M/s. Yograj Chemicals , W-28, MIDC, KURKHUMB, …environmentclearance.nic.in/writereaddata/FormB/TOR/PFR/01_Nov... · generally allocated to this account head in every annual budget

Form I and prefeasibility Report for Environmental Clearance Submitted to

State Level Expert Appraisal Committee- I

Proposal to Manufacturing 74.70 MT/Month of API and Bulk Intermediate

[Active Pharmaceutical Ingredient]

FOR

YOGRAJ CHEMICALS

Plot No W-28, Kurkumbh MIDC

Kurkumbh, Daund, Pune [MS]

Report Prepared By

Dr. Mohan Jadhav

1

INDEX

SR.

NO.

DESCRIPTION PAGE NO.

1. EXECUTIVE SUMMARY 3

2. INTODUCTION OF THE PROJECT/ BACKGROUND

INFORMATION

16

2.1 Identification of the Project and Project Proponent 17

2.2 Nature of the Project 17

2.3 Need of project with description for region and country 18

2.4 Demand and Supply Gap 19

2.5 Imports vs. Indigenous production 19

2.6 Export Possibility 20

2.7 Domestic/Export market 20

2.8 Employment generation due to project 20

3. PROJECT DESCRIPTION 21

3.1 Type of Project 22

3.2 Location of Project 22

3.3 Details of Alternate Sites 23

3.4 Size of Magnitude of Operation 24

3.5 Project Description 24

3.6 Raw material and finished products 117

3.7 Resource Optimization 117

3.8 Availability of Resource (Water, Energy/ Power Requirement) 118

3.9 Quantity of Waste to be generated 120

4. SITE ANANLYSIS 133

4.1 Connectivity 134

4.2 Land form, Land use, Land ownership 134

4.3 Topography 135

4.4 Existing land use pattern 135

2

4.5 Existing infrastructure 135

4.6 Soil classification 136

4.7 Climate data for secondary sources 136

4.8 Social infrastructure Demand 137

5. PLANNING BRIEF 138

5.1 Planning brief 139

5.2 Population Projection 139

5.3 Land use planning 140

5.4 Assessment of infrastructure demand 141

5.5 Amenities /facilities 141

6. PROPOSED INFRASTRUCTURE 142

6.1 Industrial area 143

6.2 Residential area 143

6.3 Green belt 143

6.4 Social infrastructure 144

6.5 Connectivity 144

6.6 Drinking water management 145

6.7 Sewerage system 145

6.8 Industrial waste management 145

6.9 Solid waste management 146

6.10 Power requirement & supply /source 148

7. REHABILITATION AND RESETTLEMENT 150

7.1 Policy to be adopted 150

8. PROJECT SCHEDULE & COST ESTIMATE 151

8.1 Time schedule for the project 152

8.2 Estimated project cost 152

9. ANALYSIS OF PROPOSAL 153

9.1 Financial and Social Benefit 154

3

CHAPTER 01

EXECUTIVE

SUMMARY

4

Yograj Chemicals is new unit. HFL is desirous to manufacture 23 products in this small size

industrial sector, about 74.70 MT/Month synthetic organic chemicals and API (Active

Pharmaceutical ingredients). This unit is at Plot W-28 and W-N-24 in Government MIDC

Kurkumbh, Taluka- Daund, Dist. Pune, Maharashtra. This level of production will not be

connected from day one, but will commission smoothly.

The notification number s. o. 1533 promulgated on 14th

September 2006 has covered these types

of industries under its entry 5(f). It is stated that Synthetic Organic Chemical Industry (Bulk

Drugs & Intermediates) located in a notified industrial area comes under category B. This is SSI

unit and is located notified industrial zone of MIDC Maharashtra industrial development

corporation. However the notification has not stated any exemption lower limit for the entry.

As such, with screening it is necessary for Yograj Chemicals, to approach State Experts

Appraisal committee (SEAC), Mumbai, Delegated Authority from Ministry OF Environment and

Forest (MoEF), New Delhi for environment clearance. The pre-feasibility report however is

prepared for forming a framework for EIA study, scoping and finalizing the terms of Reference,

as may be required.

JUSTIFICATION:

The public health is one of the prime considerations of the government. Large funds are

generally allocated to this account head in every annual budget of the State and Centre. By these

Government efforts India has found an excellent outcome of lowering the death rate at birth and

increasing the general length of life. The credit goes to purchasing power and also to availability

of proper medicine. Indian chemical engineers are well respected in the world and the quality of

their products.

Though many traditional disease and disorders are controlled or even eradicated, we are finding

that due to change in way of life, never ailments are prevailing

This is an important aid and there are only a few products, mostly from USA, Japan, Korea and

china. Yograj Chemicals will develop the products with in-house trials in process development

5

lab and shall take support from the experts and buy the technology and are desirous to serve the

nation by producing it here, albeit in a small scale.

The proponents are very sure to receive recognition from University, National laboratories and

Administration of Developed nations especially USFDA.

Justification of this project can be submitted on other ways as namely-

How this project is economically strong?

How the wastage is prevented?

How the pollution generated from this unit can be successfully management through EMP

implementation?

With lower pollution potential also, this industry has a justification.

SENSITIVITY:

Any proposed human activity is never a simple straight forward matter. When production is

done, the side effect of pollution takes place through the degree may vary as per alertness of the

project proponent. There are many faces of environment, and which is more sensitive depends

both on the industrial process involved as well as on the location characteristics. This must be

considered in that hierarchy, and is so considered during the scoping exercise.

In the particular case, this bulk drug manufacturing industry. However, proponent has thoroughly

examined this and has self-prescribed many conditions. In this project, air component has a

limited role to play as no raw material is gaseous in nature. Only Fuel in DG sets & boiler and

their emissions will be participating for air pollution. The stack shall be provided as per MPCB

consent conditions and monitoring platforms as per CPCB norms. Fugitive emissions shall be

controlled by smooth road surfaces, closed circuit transfers, negative pressure in reactors and tree

plantations. The some shall be scrubbed in suitable air pollution control system. Yograj has along

with W-28, area 420 Sq. M. 2 No other plots have been allotted namely E-46/1 AND E-49

having total area of 1244 Sq. M.

6

In solvent distillation and scrubber shall be provided, thus is not a sensitive issue. To maximum

extent solid waste needs attention, as it is Pharmaceutical unit, there will be hazardous waste

generating from waste lubricants, solvent distillates, process residues, spent catalyst, spent

mother liquor, discarded containers etc. this will be carefully stored in barrels or bins as per

norms. This will be under shed, roof, and parapet and on raised platform. Nothing is stored for

more than one month. This will be sent to common facility Common Hazardous Waste Storage

Treatment and Disposal CHWSTDF Ranjangaon, Pune / Cement Co processing industry.

Regular manifest system will be followed. Recycling and reuse will be done in case of Non

Hazardous solid waste.

There will be no nuisance from noise. DG set will be run occasionally only for backup power

supply during power failure. In this case majority input is odorless and only few with mild or

characteristic odor. This will be handled carefully. No nuisance will go to surrounding industries.

LOCATION:

The government has a desire to improve status of this region and hence also encouraged MIDC

industrial area. MIDC has provided the constructed sheds for easy and fast installations of the

facility. In order to have a sustainable development, the pollution generation from this industry is

finally made insignificant having taken all the precautions right from raw material selection up to

low or no waste generation and conversion.

The proposed project is on Plot No. W-28, E-46/1 and E49 are in Notified Industrial Area,

MIDC, Kurkumbh, Dist. Pune, in Maharashtra. The geographical location of this industry with

an elevation of 1664 Sq. M above mean sea level (MSL) is as follows.

Plot No. Latitude Longitude Elevation

above sea level

W-28 18.40348109 N 74.53600019 E 615 M

E-49 18.40238418 N 74.53591168 E 612 M

E-46/1 18.40250125 N 74.5363462 E 611 M

7

Government MIDC has provided all infrastructures like assured Electrical power, continuous

water supply with purification from water work. Ms. having RSF Rapid Sand Filtration and

disinfection, the internal road network, external approach road and networking with CHWSTD

(common hazardous waste storage treatment and disposal) facility at MEPL Ranjangaon /

Cement Industry.

GPS Location on Google imagery of the proposed site is attached for as (Annexure -I).

A relevant portion of MIDC MAP is enclosed (Annexure II). The proposed land is on Plot No.

W-28:420 Sq. M., E-46/1- 543 Sq. M, and E-49- 701 Sq. M. and having a readymade shed on

W-28, of 400.73 Sq. M. which shall be renovated suitable for API manufacturing.

LIST OF PRODUCTS/CATEGORY/ QTY. PER MOTH:

Sr. No. Name of the Product

Category Production Quantity

(MT/ Month)

1 Metformin Hydrochloride Anti-diabetic 25.0

2 Mefenamic acid Anti-inflammatory 5.0

3 Miconazole Nitrate Antifungal 2.0

4 Sertaconazole Antifungal 0.5

5 Warfarin Sodium Anticoagulant 0.1

6 Benfotiamine Ophthalmic 0.1

7 Gliclazide Ant diabetic 1.0

8 Alprazolam Antipsychotic 0.5

9 Etamsylate Ant palatal 4.0

10 Moxifloxacin HCl Antibiotic 4th

generation 1.0

11 Propofol Antipsychotic 2.0

12 Flunarizine Anti-Ischemic 1.0

13 Melatonin Sleep disorder 0.5

14 Ketoconazole Antifungal 1.0

15 Fluconazole Antifungal 1.0

8

16 Imidazole Ethanol Intermediate 3.0

17 Trichloroacetophenone Intermediate 3.0

18 Allopurinol Hemisulphate Intermediate 5.0

19 4-Chloro-4-Hydroxy

Acetophenone

Intermediate 2.0

20 Mannich Base Intermediate 2.0

21 Tetra butyl Ammonium Bromide

Phase transfer Catalyst 5.0

22 Phenyl Diamino Benz imidazole

sulphonic sodium salt

Cosmetic agent sun

cream

5.0

23 Mesalamine Anti-tuberculosis 5.0

-------- Total ------- 74.7

LIST OF RAW MATERIAL FOR API AND INTERMEDIATE:

Sr. No. Name of raw material Category State UOM Qty./ MT.

1. Metformin Hydrochloride

Mix-xylene Solvent Liquid Kg 1411

Dicyandiamide Reactant Solid Kg 500

Dimethyl amine

Hydrochloride

Reactant Solid Kg 658

Activated carbon Color

adsorbent

Solid Kg 2-3

Hyflo Filtration aid Solid Kg 2.3

Methanol Solvent Liquid Kg 705

2. Mefenamic acid

O-Chloro benzoic acid Reactant Solid Kg 801

2,3 Xylidine Reactant Liquid Kg 705

Sodium carbonate Reactant Solid Kg 705

Toluene Solvent Liquid Kg 2243

Carbon Adsorbent Solid Kg 25

DMF Solvent Liquid Kg 48

Hyflo Filter aid Solid Kg 16.02

Copper acetate Catalyst Solid Kg 19.20

3. Etamsylate

1,4 Dihydroquinine Reactant Solid Kg 714

Sulphuric acid Reactant Liquid Kg 571

9


Diethyl amine Reactant Liquid Kg 571

4. Fluconazole

Diflurobenzene Reactant Liquid Kg 600

Aluminium chloride Catalyst Solid Kg 700

Chloroacetyl chloride Reactant Liquid Kg 620

4-amino triazole Reactant Solid Kg 500

Methylene Di chloride Solvent Liquid Kg 13200

Isopropyl alcohol Solvent Liquid Kg 6000

Sodium nitrite Reactant Solid Kg 450

Potassium carbonate Reactant Solid Kg 540

Hydrochloric acid Reactant Liquid Kg 1000

NaOH flakes Reactant Solid Kg 380

Trimethyl sulphonium iodide Reactant Solid Kg 1100

1,2,4- Triazole Reactant Solid Kg 330

Ethyl acetate Reactant Solid Kg 2500

Methylene di chloride Solvent Solid Kg 12000

Toluene Solvent Solid Kg 800

5. Gliclazide

Octane Hydrochloride Reactant Solid Kg 625

p-Toluene sulphonyl urea Reactant Solid Kg 825

Carbon Adsorbent Solid Kg 31.25

Methylene di chloride Solvent Liquid Kg 5000

Acetonitrile Solvent Liquid Kg 3125

Hyflo Reagent Solid Kg 18.75

6. Miconazole nitrate

Trichloroacetophenone Reactant Solid Kg 1111

Toluene Solvent Liquid Kg

Sodium carbonate Reactant Solid Kg 888

Imidazole Reactant Solid Kg 888

Tetra butyl ammonium

Bromide

Catalyst Solid Kg 111

Sodium Borohydride Catalyst Solid Kg 138.80

NaOH flakes Reactant Solid Kg 27.70

Methanol Solvent Solid Kg 555.55

Benzoyl chloride Reactant Liquid Kg 1111

Nitric acid Reactant Liquid Kg 555

7. Sertaconazole

2,4 [ Dichlorophenyl]-2-(1-

Imidazole Ethanol)


1-( Bomomethyl)-7-chloro-1-

Benzothiopen



10

Acetone Solvent Liquid Kg 13888

NaoH flakes Reactant Solid Kg 583


Tetra Butyl Ammonium

Bromide

Catalyst Solid Kg 55.50


Nitric acid 70 % Reactant Liquid Kg 444.40

8. Warfarin sodium

4-Hydroxy Coumarine Reactant Solid Kg 833

Benzal acetone Reactant Solid Kg 966


Isopropanol Solvent Liquid Kg 8333

NaOH flakes Reactant Solid Kg 250

9. Propofol

Isopropanol Reactant and

solvent

Liquid Kg 1000


4-Hydroxy Benzoic acid Reactant Solid Kg 1300

50% NaOH lye Reactant Liquid Kg 8107

Conc. HCl Reagent for

Neutralization

Liquid Kg 6000


Hyflo Filter aid Solid Kg 20


Toluene Solvent Solid Kg 6000

Sodium Bi Carbonate Reagent Solid kg 69.20

10. Flunarizine

4.4-Difluoro Methanone Reactant Solid Kg 1014


Ethyl Acetate Solvent Liquid Kg 31250

HCL 30% Reagent Liquid Kg 5425

Calcium Chloride Reagent Solid Kg 724.8


Sodium Borohydride Catalyst Solid Kg 270

Piperazine Reactant Solid Kg 375

Sodium Sulphate Reagent Solid Kg 1475

Cinamyl bromide Reactant Solid Kg 500

Potassium Carbonate Reagent Solid kg 1000

Carbon Adsorbent Solid kg 52.08

Hyflo Reagent Solid kg 26.04

11. Melatonin

5-Methoxy Tryptamine Reactant Solid Kg 1250

11

Hydrochloride

Pyridine Catalyst Liquid Kg 1250

Acetic anhydride Reactant Liquid Kg 1250

Dimethyl Sulphoxide Solvent Liquid kg 3750

Ethyl Acetate Solvent Liquid kg 7500

Carbon Adsorbent Solid kg 75

Hyflo Reagent Solid kg 50

HCl Reagent Liquid kg 375

12. Alprazolam

2-Amino-5-Chloro

Benzophenone


Acetic acid Solvent Liquid Kg 4032

Chloro acetyl Chloride Reactant Liquid Kg 483


Phosphorous Pentasulphide Reactant Solid Kg 1222

Hexamine Reagent Solid Kg 2636

Ammonium Carbonate Reagent Solid Kg 618


Isopropanol Solvent Liquid Kg 5000

Sodium carbonate Reagent Liquid Kg 977

Xylene Solvent Liquid Kg 8636


Acetyl Hydrazine Reactant Solid Kg 900


Acetonitrile Solvent Liquid kg 7777

13. Benfotiamine

Thiamine Hydrochloride Reactant Solid Kg 1562

O-phosphoric acid Reactant Liquid Kg 1937


Benzoyl chloride Reactant Liquid Kg 593

Phosphorous pent oxide Reactant Solid Kg 1937

15% NaOH Reactant Liquid Kg 937

Acetic acid Solvent Liquid Kg 625


Hyflo Filter aid Solid kg 62.50

14. Ketoconazole

Cis-tosylate Reactant Solid Kg 880

n-acetyl-4-(4-hydroxyphenyl

piperazine)


DMSO Solvent Liquid Kg 1363

NaOH flakes Reactant Solid Kg 95.45

Sodium methoxide Reactant Solid Kg 131.80

Acetone Solvent Liquid Kg 4545

12

Ethyl acetate Solvent Liquid Kg 8181


Act. Carbon Adsorbent Solid Kg 45

Hyflo Filtration aid Solid Kg 18

15. Moxifloxacine Hydrochloride

Cyclo propane Di Fluoro

Quinolie Carboxylic acid


CisDiazabicycloNonane Reactant Solid Kg 760

Acetonitrile Solvent Solvent Kg 1200

Methanol Solvent Solvent Kg 1000

Dimethyl Formamide Solvent Solvent Kg 200


Hyflo Reagent Solid kg 8

16. Phenyl Di amino Benzimidazole Sulphonic sodium salt

3,4 Diaminosulphonic acid Reactant Solid Kg 816

Benz aldehyde Reactant Solid Kg 358.97

NaoH flakes Reagent Solid Kg 80

Water Solvent Liquid Kg 5100

Sodium Di Thionate Reagent Solid Kg 8.16


Hyflo Reagent Solid Kg 12.24

1. Allopurinol intermediate- 5-Amino-pyrazole-4-carboxymide-hemisulphate

Cyanoacetamide Reactant Solid Kg 1785

Triethylorthoformate Reactant Liquid Kg 5000

Morpholine Reactant Liquid Kg 1071

CMA Solvent Solvent Liquid Kg 5000

Hydrazine Hydrate Reactant Liquid Kg 1071


2. Tramadol Hydrochloride- Mannich base (Intermediate)

Formaldehyde Reactant Solid Kg 280

Cyclohexanone Solvent Liquid Kg 2230

HCL 30% Reactant Solid Kg 307

DMA HCl Reactant Liquid Kg 724.60

NaOH lye Reactant Liquid Kg 876


3. 4-chloro-4-hydroxy benzophenone (Intermediate finofibrate)

Aluminum chloride (ALCL3) Catalyst Solid Kg 800

Ortho Di Chloro Benzene

(ODCB)

Solvent and

Reactant Liquid

Kg 1714

Phenol Reactant Semisolid Kg 537

P-Chlorobenzoyl Chloride Reactant Reactant Kg 994

Toluene Solvent Solvent Kg 6857

13

Acetone Solvent Solvent Kg 800

Activated carbon Adsorbent Solid Kg 5.70

4. Tri Chloro acetophenone

1,3 Di Chloro Benzene Reactant Liquid Kg 833

Aluminium Chloride Catalyst Solid Kg 1016

Chloro acetyl chloride Reactant Liquid Kg 916

HCL 30% Reagent Liquid Kg 166

Water Solvent Liquid Kg 5833

5. Imidazole ethanol

Tri Chloro acetophenone Reactant Solid Kg 1111

Toluene/THF Solvent Liquid Kg 5466

Sodium Carbonate Reagent Solid Kg 888

NaOH Reagent Solid Kg 27.70

Sodium Borohydride Reagent Solid Kg 138.80

6. Tetra Butyl Ammonium Bromide

n- Butyl Amine Reactant Liquid Kg 600

n-Butyl Bromide Reactant Liquid Kg 800


Ethyl acetate Solvent Liquid Kg 220

7. Mesalamine

5-Chloro-2-Nitro Benzoic

acid


Potassium Hydroxide Reagent Solid Kg 164

Hydrochloric acid. 30 % Reagent Liquid Kg 2000

Sodium Carbonate Reagent Liquid Kg 592

Raney Ni Catalyst Solid Kg 145

Hydrogen Gas Reactant Gas M3

509

PLOT FORM:

The shed and Land is on plain contour, it is flat terrain. MIDC readymade shed allotted. Yogiraj

Chemicals has 3 no plots Namely W-28, E-46/1 and E-49. Out of which W-28 has an

infrastructure in place [Construction shed]

PLOT OWNERSHIP:

Land and shed ownership is with proponents.

14

EXISTING LAND USE PATTERN:

The land is reserved for industrial use, few trees and grass is present at the site, which will be

retained for Landscape Development. Plot No W-28 is having MIDC constructed shed, Plot E-

46/1 and E-49 are empty and allotted to Yograj Chemicals.

EXISTING INFRASTRUCTURE:

Presently there is an existing infrastructure at the site W-28. Infrastructure like water, electricity,

telephone facility, roads already available as this is an industrial area.

Other infrastructure like, hospital, school, housing entertainment, daily needs are available easily

at Daund town which is 6 km from site.

Transport infrastructure like Airport and Railway is also available. The distance of Domestic

Airport in Pune is 75 km from the site at North West direction. Nearest Railway station is

Daund which is 9 km from the area.

Yograj Chemicals is desirous to establish new unit in plot having MIDC constructed shed and 2

No open plots with proposing a 74.7 MT/Month product of Active pharmaceutical ingredients

and intermediates required especially by pharmaceuticals

Whereas water input requires 59 M3/day

Briquette-150kg/hr. will be used & there will be 0.750 TPH boiler (750 kg/Hr. 1 Nos.), which

will produce steam.

All the 3 No plots are in the vicinity and shall be appropriately used for developing the facility

for manufacturing API.

ETP, Solvent and Raw material warehouse shall be developed on the plot E-46/1 and E-49.

In Yograj Chemicals safety and occupational health will be dealt carefully. A disciplined

approach shall be natural to this industry. Safety policy will be in place. This unit shall be

registered under factories act and shall be bounded by State Factory Rules. Thus, first aid trained

and firefighting trained person will be available in every shift. Shift Production officer will be

appointed having knowledge of fire hydrant and handling firefighting knowledge. Wherever

15

necessary, provisions of other acts will be obeyed. Firefighting system will be kept as per norms.

Industry shall obtain the fire NOC from Chief fire officer MIDC.

DMP (Disaster Management Plan) and off-site emergency plan will be in place. Accordingly,

personal protection equipment will be given and use will be insisted. Consulting physician will

be retained to attain the factory.

This proposed Synthetic Organic Chemicals facility at Plot No. W-28, Kurkumbh, Tal. Daund,

Dist.-Pune, Maharashtra. The site is 9 km from Daund railway station. The land and

infrastructure is made available by MIDC and the raw material is easily available through the

easy transport via road connectivity.

The industry will manufacture synthetic ACTIVE PHARMACEUTICAL INGREDINTS and

organic Intermediates which are in good demand for growing Medical facilities in India. This

will not disturb the present land use because our area occupied will be only small % of influence

zone 10 km. this land and shed is in industrial estate. Trees will be maintained and razed down.

No rehabilitation is involved. There will be no any type of Hazardous or nonhazardous waste

materials as all will be disposed as per CPCB norms.

16

CHAPTER 02

INTRODUCTION OF

THE PROJECT /

BACKGROUND

INFORMATION

17

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT:

M/s Yograj Chemicals has proposed for producing 74.70 MT/Month of Active pharmaceutical

ingredients and intermediates. Yogiraj Chemicals desire’s to produce their 23 products at Plot

No. W-28, Kurkumbh Industrial Area, Kurkumbh, Tal. Daund, Dist. Pune, Maharashtra.

However, the notification has not stated any exemption lower limit for this entry. As such, with

screening it is necessary for Yograj Chemicals to approach State Experts Appraisal Committee

(SEAC) Mumbai, Delegated Authority for Environmental Clearance for guidance for this unit.

This Pre-feasibility Report is prepared for forming a framework for EIA study, scoping and

finalizing the Terms of Reference, as may be required.

Though many traditional diseases and disorders are controlled or even eradicated, we are finding

that due to change in way of life, newer ailments are prevailing.

The Form- I submitted covered justification, nearby Land use, Resources, Process, Pollution

Control, Aesthetics, Risk Involved, Consequence Developments and Environmental Sensitive

issues.

Form I, as is prescribed by the said Notification is duly filled up and submitted. This pre-

feasibility Report is an accompaniment to the same.

2.2 NATURE OF THE PROJECT:

Yograj Chemicals is proposing Project producing Synthetic Organic Chemicals/API. This level

of production 74.7 MT/Month will be commissioned smoothly. This is an optimum site for use

because it is manageable from production, pollution control and quality assurance point of view.

STORAGE AT SITE:

All finished goods & Raw materials, fuels will be stored at site and an additional nearby plots

namely E-46/1 and E-49 admeasuring 1244 Sq. M has been allotted to M/S Yograj Chemicals, in

an appropriate manner. Storage as per Norms shall be provided for Raw material, finished

products, solvents, chemicals etc. Safety norms shall be followed for the storage. Tank farm shall

be provided for the storage of solvents depending upon the daily consumptions & liquid

18

chemicals, fuels. Well ventilated warehouse shall be provided for Raw Material & products.

Finished product storage area shall be separate and as per FDA norms.

MODE OF TRANSPORT:

The mode of transport shall be via Road/Rail. Maximum Transportation shall be by road.

Required raw materials shall be transferred from this plot to the said plot where a manufacturing

block shall be made by renovating the existing shed allotted by MIDC suitable for API and

Intermediate manufacturing.

MARKETING (DOMESTIC AND EXPORT POSSIBILITIES):

Marketing will be done at local level, exported to non-regulated international market as well as

to the semi regulated and at the latter stage to regulated international market after the unit gets

audited and approved by the respective regulatory agencies.

INSTALLED CAPACITY OF THE PROPOSED PROJECT:

The proposed capacity of project will be 74.70 MT/Month.

PRODUCTION PROTOCOL:

Production will be as per demand and supply. The products will be changed as per the demand

supply.

2.3 NEED OF PROJECT WITH DESCRIPTION FOR REGION AND COUNTRY:

The public health is one of the prime considerations of the government. Large funds are

generally allocated to this account head in every annual budget of the state and center. By these

governmental efforts India has found an excellent outcome of lowering the death rate at birth and

increasing the general length of life.

Though many traditional diseases and disorders are controlled or even eradicated, we are finding

that due to change in way of life, newer ailments are prevailing.

19

This is an important aid and there are only a few, mostly from producers USA, Japan, Korea and

China. Yograj Chemicals will develop this product by in-house trials and technology of some

shall be hired from the experts, and are desirous to serve the nation by producing here, albeit in a

small scale.

Thus, such units have a justification. Yograj Chemicals shall obtain the requisite approval and

license from local FDA. Yograj Chemical will establish a process development laboratory and

seek the support of well qualified authority having a vast experience in this field. The proponents

hope to receive recognition from university, national laboratories and administrations of

developed nations especially USFDA. At the latter stage and once it starts selling the products in

local and international market.

2.4 DEMAND AND SUPPLY GAP:

Day by day population is increasing and in similar way the requirement of the basic needs like

Medicines, which are very essential for everyone is also increasing and there is a need to supply

required medicines at an affordable price.

Due to the change in lifestyle & simultaneously increasing population newer ailments & diseases

are prevailing. For these new ailments demand of medicines is increasing. To cope up with the

incasing demand, we are introducing new molecules, so that the demand & supply gap can be

filled. With the introduction of new products, cost of these products will be more economically

viable.

2.5 IMPORTS VS. INDIGENOUS PRODUCTION:

Raw material is easily available in the local market; some of the raw materials will be procured

from the international Market.

The medicines which are essential for Indian market will be produced to fulfill the need of

medicine of nation and reduce their import from international market.

20

2.6 EXPORT POSSIBILITY

Marketing will be done at international level as well as finished goods will be exported to the

regulated and non-regulated international market. Market shall be explored with traders having

Google contacts and having rich experience till Yograj Chemicals employees own team of

marketing department.

2.7 DOMESTIC / EXPORT MARKET

Marketing will be done at local level, exported to non-regulated international market as well as

to the regulated international market.

2.8 EMPLOYMENT GENERATION DUE TO PROJECT

Employment will be generated for administration and production purposes and will be recruited

locally without any difficulty.

Indirect employment shall be through road-side business & allied activities. Total 15 skilled and

unskilled workers shall be employed at this facility.

21

CHAPTER 03

PROJECT

DESCRIPTION

22

3.1 TYPE OF PROJECT

Yograj Chemicals is proposing, synthetic organic chemicals/ API manufacturing unit with 74.7

MT/Month of capacity.

In order to have a sustainable development, the pollution generation from this industry is finally

made insignificant having taken all the precautions right from raw material selection up to low or

no waste generation and conversion.

3.2 LOCATION OF PROJECT

The proposed production shall be at Plot No. W-28, Industrial area, Kurkumbh, Tal. Daund, Dist.

Pune. Maharashtra. The Geographical location of this industry with an elevation above mean sea

level is as follows.


above sea level

W-28 18.40348109 N 74.53600019 E 615 M

E-49 18.40238418 N 74.53591168 E 612 M

E-46/1 18.40250125 N 74.5363462 E 611 M

This candidate site is in premises- of Industrial Area which is meant or various types of

industries.

A lot industry has set up the units and is very comfortable with the infrastructure. Government

has provided all infrastructure like electrical power, continues water supply with purification

from water works having RSF( Rapid Sand Filtration) and disinfection, the internal road

network, external approach road, and networking with CHWTSDF (Common Hazardous Waste

Storage Treatment and Disposal Facility) at Ranjangaon, Pune, I /MEPL Rajangaon /Cement

Factory.

GPS location and Google imagery of the proposed sites are attached as (Annexure-I).

A relevant portion of MIDC map is enclosed as (Annexure-II).

23

The proposed land is at Plot No.W-28 admeasuring 420.00 Sq. Mt., E-46/1, and E-49

admeasuring 1244 Sq. M.

3.3 DETAILS OF ALTERNATE SITE

Plot E-46/1, E-49, in the vicinity of W-28, has been allotted to Yograj for necessary

infrastructure of ETP .Raw material/Finished product storage and solvent distillation systems.

This site [ Both Plots ] are inside the campus of the MIDC and means safe transportation, less

need of Utilities, less construction of roads, less fuel, less water with optimization of

infrastructure. .

Transport infrastructure like Airport, Railway, and Bus Station is approachable. Airport is at the

distance of 75, Km from the project site and Railway Station is at Daund, which is about 9 km in

North West, direction.

Other Infrastructure like, hospital, school, housing, entertainment, daily needs are available

easily at Daund, Pune village which is 9 km from the plot site.

There is no sensitive establishment in the vicinity such as health resort, hospital, archaeological

monuments, sanctuaries, etc. All nearby villages are provided with drinking water from wells or

Government Water Supply Schemes. Hence we do not encroach upon their supply.

With all this consideration, this site was ranked first and adopted.

The location justification for the project is as under

a. Availability of required land and readymade shed for locating the Synthetic Organic

Chemicals Plant.

b. Suitability of land from topography & geological aspects.

c. Proximity to rail/ road to facilitate transport of equipment/ materials.

d. Availability of adequate quantity of fuel and fuel transport facility.

e. Availability of adequate quantity of water to meet cooling and DM water

requirements.

f. Facility for interconnection with distribution system for power.

24

LAY-OUT

Layout is designed properly. It is proposed to modify and make construction to house facility for

intermediate and finished products, ware houses, utility building, pilot plant and administrative

offices. In addition to this plant, waste minimization or solvent recovery unit, sophisticated

laboratory will be required and shall be provided.

The Layout of facility shall be prepared based on following:

1. There shall be sufficient space for the movement of vehicles especially fire tender.

2. Shortest route for transfer of material from one department to other.

3. Consideration of prevalent Wind speed & direction for dispersion of flue gases.

4. Optimum Utilization of utilities.

5. Use of Natural gradient to transport waste water.

Proposed Layout Plan is given as (Annexure III).

3.4 SIZE OR MAGNITUDE OF OPERATION

The total magnitude of operation is 74.70 MT/Month product size Unit producing Synthetic

Organic Chemicals.

3.5 PROJECT DESCRIPTION WITH PROCESSES DETAILS

MANUFACTURING PROCESS

Any kind of product or intermediate shall follow all or some of the steps as mentioned in the

flow diagram. These reactions may occur at different temperatures & pressure. As per the

requirement of the product raw materials, solvents, catalysts etc. shall be used.

1. NAME OF THE PRODUCT

5-Amino- Pyrazole- 4-Carboximide (5.0MT/Month)

BRIEF DESCRIPTION OF PROCESS

Cyanoacetamide is reacted with Triethyl Orthoformate and Morpholine followed by distillation

to precipitate CMA. The product is further isolated by centrifugation as .Stage I, CMA is

25

converted to APCHS by reacting with Hydrazine hydrate in water followed by addition of

Sulphuric acid to precipitates 5 amino –Pyrazole -4 Carboximide Hemisulphate [APCHS]. The

Product is isolated by centrifugation and dried to give finished product used as intermediate for

Allopurinol.

SYNTHETIC ROUTE

26

PROCESS FLOW DIAGRAM

Cyanoacetamide, Triethyl formate Rec. Ethanol for sale recycler

Morpholine, Isopropyl Alcohol

Stage I, Hydrazine Hydrate ML to ETP for Treatment

Sulphuric acid, Water

Water for washing ML to ETP

Hemisulphate

REACTOR

REACTOR

CF

DRYER

27

TABLE NO I: INPUT, OUTPUT AND MASS BALANCE: - ALL FIGS IN KG

Input Qty. Output Qty. Remarks

Cyanoacetamide 0.50 Product stage I 1.4 Product to be used for next

Reaction Triethyl

orthoformate

1.4 Ethanol 1.0 Spent solvent sale to

Authorised Recycler

Morpholine 0.8 Solvents

Isopropyl Alcohol 1 Isopropyl alcohol 0.75 Recovery and reuse

Isopropyl alcohol 0.25 Fugitive loss.

Isopropyl Alcohol 0.25 Evaporation and operational

loss Solvent Residue Nil Nil

Un reacted Organics

Cyanoacetamide 0.1 Organic Residue

Triethyl orthoformate 0.1 Organic Residue

Morpholine 0.1 Organic Residue

Effluent. HCOD,

LCOD The reaction is solvent based

Nil

Total Input 3.70 Total Output 3.70

1. Stage I: - Reaction is not exothermic or toxic. There is no pressure required for the

reaction.

2. None of the raw material has any hazardous nature.

TABLE NO II – STAGE II - INPUT, OUTPUT AND MASS BALANCE.

Input Quantity

(Kg)

Output Quantity

(Kg)

Remarks

CMA 1.4 Stage II 1.4 Stage-II Product

Hydrazine Hydrate 0.30 Solvent

Sulphuric acid 0.80 NIL NIL No solvent used

Water 4.10 Effluent

HCOD 4.1

Send to ETP for treatment

LCOD

28

Un reacted Organics

Stage I Nil -----

Morpholine

sulphate 1.1

Organic By product for sale

Total Input 6.6 Total

Output 6.6

1. The Reaction is not Exothermic or run away or pressure.

2. Hazardous raw material used. 1] Sulphuric acid.

3.

TABLE NO III: POLLUTION LOAD: - ALL FIGS IN KG EXCEPT EFFLUENT.

Stage Effluent in

Lit

[ Waste water]

ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Inorganic

Salt

Organic

Residue

LCOD HCOD

I ------ ---------- ------ ------ -------- ------ 3570 -- ------- 3000

II ------- 14285 -------- -------- ------ ------- -------- ----- 3928 ------

A-Pollution load per month

------ Nil 14285 ------ -------- ------- ------ 3570 ---- 3928 ---------

B-Pollution load per day

------ Nil 476 -------- -------- -------- ------- 119 ---- 130 100

29

NAME OF PRODUCT

Propofol (2.00 MT/Month)


P-Hydroxy benzoic acid and isopropyl alcohol is reacted in the presence of conc. sulphuric acid. The

reaction mass is treated with sodium hydroxide in Toluene and HCL to give 3,4- Di Isopropyl –P-

Hydroxy Benzoic acid.[DPHB]. This DPHB is purified in Methanol, carbonized and filtered through

hyflo bed. The filtrate is cooled and the product is centrifuged, unloaded and dried as Stage I. Stage-I

is treated with ethylene glycol and caustic flakes and to the reaction mass water is added. The

product is extracted in Toluene. The toluene extract is washed with sodium bicarbonate solution. The

Toluene extract is subjected for vacuum recovery to get crude Propofol. Crude Propofol is further

distilled under high vacuum to get pure propofol.

ROUTE OF SYNTHESIS

Stage- I

Mol. Wt. 138 60 98 18 222

OH

OOH

p-hydroxy

benzoic acid

+OH

+ Conc. H2SO

4+ H

2O

Tol. /

50% NaOH

OH

OOH

IPA Sulphuric acid 3,5-diisopropyl p-hydroxy

benzoic acid

Stage-II: Preparation of 2, 6-diisopropyl phenol

Mol. Wt. 222 40 178

+ NaOH

OH

OOH

Sodium

hydroxide3,5-diisopropyl p-hydroxy

benzoic acid

OH

2,6-diisopropyl phenol

140 - 145°C

Ethylene glycol, N2 gas

30

Stage-III: Purification of crude propofol by high vacuum distillation:

Mol. Wt. 178 178

OH

Pure Propofol

OH

Crude Propofol

HVD

0.2 - 0.5 mm of Hg

31

PROCESS FLOW DIAGRAM:

4- Hydroxy Benzoic acid

Isopropanol / Sulphuric acid

50 % NaOH / Toluene

Water

Aq. layer to ETP

Toluene Recovery

Ml for solvent recovery

Solvent residue

Methanol, Carbon, Hyflo

Carbon/Hyflo

Methanol Ml for recycling

REACTOR

SE

P

REACTOR

CF

REACTOR

FILTER

REACTOR

CF

32

Ethylene Glycol, Water

NaOH Lye CO2 gas to air

Toluene

Aq. layer to ETP for treatment

Sodium carbonate solution

Aq. layer to ETP for treatment

Toluene Recovery and use

ML for solvent recovery

Residue for HW disposal

High vacuum distillation Residue for HW disposal

Pure Propofol

REACTOR

High tem

Reaction

SE

P

REACTOR

SE

P

REACTOR

REACTOR

HIGH

VACUUM

DISTILLATION

33

TABLE NO I. STAGE I: - INPUT, OUTPUT AND MASS BALANCE

No Input Name UOM Qty. Output name Qty. Remark

1 P-Hydroxy

Benzoic acid

Kg 1.30 Stage I product 1.3 Stage Final product

2 Conc. Sulphuric

acid

Kg 8.60 Solvent

3 Isopropyl alcohol Kg 1.69 Toluene 7.41 Recovery and use

4 50% NaOH lye Kg 10.54 Toluene 0.39 Evaporation and

process loss

5 Conc. HCl Kg 7.80 Methanol 4.05 Recovery and use

6 Methanol Kg 5.07 Methanol 1.02 Process operational

loss

7 DM Water Kg 41.60 Sodium chloride 1.96 In aq. effluent

8 Hyflow Kg 0.026 Sodium Sulphate 7.548 In aq. effluent

9 Activated Carbon Kg 0.026 Effluent

10 Toluene Kg 7.80 Effluent HCOD 60.72 ETP for treatment

Effluent LCOD Nil ----------------

Activated carbon 0.026 HW CHWTDS

Hyflow 0.026 HW CHWTDS

Total Kg 84.452 Total 84.452

TABLE NO II: - STAGE –II: - INPUT, OUTPUT AND MASS BALANCE

No Input UOM Qty. Output Qty. Remark

1 Stage I Kg 1.30 Crude Propofol 1.53 Stage II crude

product

2 Ethylene Glycol Kg 1.95 Solvent

3 Caustic Flakes Kg 0.747 Toluene 10.26 Recovery and use

4 HCl solution Kg 3.60 Toluene 0.54 Operational and

evaporation loss

5 Water Kg 23.40 Sodium chloride 0.06 In aq. Effluent

6 Toluene Kg 10.80 Effluent

7 Sodium Bi

Carbonate

Kg 0.09 Effluent HCOD 29.49 ETP for treatment

Effluent LCOD Nil ------------------

Total Kg 41.88 Total 41.88 ----------------

34

TABLE NO III: - STAGE III:--INPUT, OUTPUT AND MASS BALANCE

No Input Name UOM Qty. Output name Qty. Remark

1 Crude Propofol Kg 1.53 Propofol pure 1.0 Final product

Distillation loss 0.18 ------------

Organic Residue 0.35 HW –CHWTDS

Total Kg 1.53 Total 1.53 -----

TABLE NO: - IV- POLLUTION LOAD. ALL FIGS IN KG EXCEPT EFFLUENT

Stage Effluent in L

ETP

Residue

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas

Generated

In

organic

Salt

Org.

Residue

LCOD HCOD Name Qty.

I 4000 87307 3500 ------ 40 40 ------- ------- ------ ------- -----

II ------

-

385 ------ ------- ------- ------- ------- -------

--

-------

-

---------- --------

III ------

---

---------

--

--------- -------- 40 40 -------- -------

--

-------

--

--------- 700

Pollution load per Month A, B- Pollution load per day

A 4000 87692 3500 -------- 40 40 -------- -------

----

------- ---------- 700

B 133.3

3

2923 116.66 -------- 1.33 1.33 -------- -------

-

------- --------- 23.33

No pressure Reaction or Exothermic reaction.

High vacuum distillation in final stage.

Toxic raw materials: - 1. Sulphuric acid 2. Caustic 4. Toluene.

TABLE NO IV- GAS GENERATED, RELEASED/DAY

Stage Name of the

Gas

UOM Qty. Remark

I Nil Kg Nil Nil

II Nil Kg Nil Nil

III Nil Kg Nil Nil

35

NAME OF PRODUCT

Trichloroacetophenone (3.00 MT/Month)


m- Dichloro Benzene is charged in a glass line reactor and cooled to 10 0C.

Aluminum chloride

is charged maintaining temperature of the reaction mass in the range of 10-15 0C.

After complete addition of Aluminum chloride stir the reaction mass for ½ hr. and start addition

of Chloro acetyl chloride to the reaction mass, in the temperature range of 10-15 0C.

Stir the reaction mass for ½ hr. and the heat the reaction mass to 45-50 0c

maintain for 3 hrs.

Check TLC for reaction completion. Cool the reaction mass and quench in acid water. Stir and

centrifuge. Wash with plane water till neutral pH. Unload and dry in tray dryer at 40 0c.

SYNTHETIC ROUTE

36


m-Di chloro Benzene

AlCl3

Chloro acetyl chloride

Ice cold water/HCl

Water for washing ML to ETP for treatment

Trichloroacetophenone

REACTOR

Quencher

CF

DRYER

37

TABLE NO I: - INPUT, OUT AND MASS BALANCE

Sr.

No.

Input UOM Qty. Output Qty. Remark

01 MDCB KG 100 TCAP 120 Product

002 AlCl3 Kg 122 Aq. ML 712.40 HCOD effluent to ETP for Treatment

Contains Alcl3 , unreacted CAC,

resulting into ETP sludge

003 CAC Kg 110 HCL gas 19.60

Scrubbed in scrubber

004 HCl Kg 20

005 Water Kg 500

006 Water Kg 200 Aq

Effluent-

LCOD

200 Send to ETP for treatment

Total Kg 1052 Total 1052 -----------------

MDCB- m-Dichloro Benzene CAC- Chloro acetyl chloride HCl- Hydrochloric acid.

TABLE NO II:-POLLUTION LOAD.

Stage

Effluent in

Lit

ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas generated In

Org.

Salt

Org.

Residue

LCOD HCOD Name Qty.

I ----- 5000 ------ ------- -------- ------- ------- HCl 490 ------ ----------

Pollution load per month

----- 5000 ------ ----------

--

-------- -------- ------- HCl 490 ------

-

-------

Pollution load per day

----- ------ ----- ------ ------ ------- ------ HCl 16.33 ------ -----

NO pressure reaction. No exothermic reaction

Toxic and hazard raw material 1. Chloro acetyl chloride 2.m-Di- Chloro acetyl

Chloride. Aluminum Chloride.

GAS GENERATION OR RELEASED/DAY

Sr.No Name of the Gas UOM Qty. /Day Remark

1 Hydrochloric acid Kg 16.30 Scrubber provided,

38

NAME OF PRODUCT

Sertaconazole (500 kg/Month)


Imidazole Ethanol and 1-Bromo Methyl -7- chloro-1- Benzothiopen are condensed in Toluene

as solvent in presence of Alkali and TBAB. After the reaction s complete the reaction mass is

cooled and then water is added. The product is filtered, slurred in water, centrifuged washed with

methanol/water, spin dried and unloaded. The product is crude sertazonazole base. The base is

dried, then charged in acetone and refluxed. Acetone is distilled off to get product which is

further slurred in toluene and centrifuged and washed with Toluene and then dried to get Pharma

Sertaconazole.

SYNTHETIC ROUTE

-

39


1-Bromo3 Methyl 7-chloro

Benzothiazopen

Toluene

Imidazole Ethanol

TBAB/Water

Water wash ML for solvent recovery

ML for solvent

Toluene/ Methanol for Recovery

Solvent Recovery

SERTACONAZOLE

REACTOR

Centrifuge

REACTOR

CF

DRYER

40

TABLE NO I: - INPUT, OUTPUT AND MASS BALANCE

Sr.

no

Input UOM Qty. Output

Qty.

Remark

1 2,4 [ Dichlorophenyl]-2-

(1-Imidazole Ethanol)

Kg 15 Product 18 Final Product

2 1-( Bomomethyl)-7-

chloro-1-Benzothiopen

Kg 13.5 Toluene 100

Recovery and use

3 Toluene Kg 120 Toluene 10 Evaporation loss

4 NaOH flakes Kg 10.50 Na Br 4.24 Sale

5 Water Kg 500 Methanol 75 Recovery and use

6 TBAB Kg 1.0 Acetone 160 Recovery and use

7 Methanol Kg 103 Carbon 3 HW Disposal

8 Acetone Kg 250 Water

Effluent

600 HCOD to ETP for

treatment

9 HNO3 Kg 8.0 Solvent

residue

53.76 HW Disposal

10 Carbon Kg 3.0

Total Kg 1024 Total 1024 ----------------------

TBAB: - Tetra Butyl Ammonium Bromide.

TABLE NO I: - POLLUTION LOAD (ALL FIGS IN KG EXCEPT EFFLUENT)

Stage Effluent in Lit

ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas

Generated

In

organic

Salt

Organic

Residue LCOD HCOD Name Qty.

I 4000 12200 Nil 1451.20 81 ----- ------- ------ ------ 114.48 ------

Pollution load per Month

------ 4000 12200 ------- 1451.20 81 -------- ------- ------- ----- 114.48 ------


------ 133.3 406.6 -------- 48.30 2.70 ------- -------- ------- ----- 3.82 -----

No pressure or exothermic reaction.

Toxic raw materials—1. Raw material 2. Toluene.

41


Sr.

No.

Name of the Gas UOM Qty. /Day Remark

1 Nil Kg Nil -------------

42

NAME OF PRODUCT

Gliclazide (1.0 MT/Month)

BRIEF DESCRIPTION OF THE PROCESS

Amino azabicyclo octane Hydrochloride and P-Toluene sulphonyl urea are condensed in

acetonitrile to get Gliclazide. The crude is purified in methylene di chloride. Recovered

methylene di chloride is recycled for next successive batches.

ROUTE OF SYNTHESIS

43


Octane HCL

Acetonitrile

P-Toluene Sulphonyl urea

Acetonitrile ML for recovery

Methylene di Chloride

Carbon, Water REC.MDC

Carbon as HW

ML to ETP for treatment

Gliclazide

REACTOR

NF

Filter

REACTOR

FILTER

REACTOR

CF

DRYER

44

TABLE NO I:-STAGE I: INPUT, OUTPUT AND MASS BALANCE

No Input UOM Qty. Output Qty. Remark

1 Amino octane

hydrochloride

Kg 100 Gliclazide 160 Final Product

2 P-Toluene sulphonyl

Urea

Kg 132 Acetonitrile 480 Recovery and recycle

3 Acetonitrile Kg 500 Acetonitrile 20 Evaporation and process

loss 4 MDC Kg 800 MDC 740 Recovery and use

5 Carbon kg 5 MDC 10 Evaporation and process

loss

6 Hyflo kg 3 Carbon 5 HW Disposal

7 Water kg 100 Hyflo 3 HW Disposal

Spent Aqueous

Effluent

186 ETP for treatment

Solvent

distillation residue

36 HW Disposal

Total kg 1640 Total 1640 ----------------

MDC- Methylene Di Chloride

TABLE NO II:-POLLUTION LOAD (ALL FIGS IN KG, EXCEPT EFFLUENT)

Stage Effluent in Lit.

ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Generated

Inorganic

Salt

Organic


I 1162.5

0

--------- ------- 225 31.50 18.75 ------- ------ ------- ------ ------


1162.5

0

------ ------ 225 31.50 18.75 ------- --------

--

-------- ------- ------


38.75 -------- -------- 7.50 1.05 0.625 -------- --------

-

------- ------ -----

1. No pressure reaction, 2. No gas of any type is generated during the reaction.

2. Toxic, Hazardous Chemicals – MDC, [Methylene Di Hydrochloride]


Sr. No. Name of the Gas UOM Qty. /Day Remark

1 Nil Kg Nil Nil

45

NAME OF PRODUCT

Etamsalyte (4.00MT/Month)

BRIEF PROCESS DESCRIPTION

1, 4 Di Hydro quinine is treated with sulphuric acid and then condensed with diethyl amine.

The resultant product is dissolved in methanol and carbonized. The filtrate is cooled and product

obtained as Etamsylate is centrifuged washed. Unloaded and then dried.

ROUTE OF SYNTHESIS

46


1,4- Dihydro quinine.

H2SO4

ML for waste disposal

Methanol

Diethyl amine

ML for recovery of II nd

crop

and Methanol for recycling.

Etamsalyte.

REACTOR

CF

REACTOR

CF

DRYER

47

TABLE NO I: STAGE I: - INPUT, OUTPUT AND MASS BALANCE

No Input Name UOM Qty. Output name Qty.

1 1.4 Dihydro Quinone Kg 250 Product 350 Etamsalyte

2 Sulphuric acid Kg 200 Acid residue spent 230 Waste Disposal

3 Methanol Kg 250 Recovered

Methanol

235 Recovery and

recycled

4 Diethyl Amine Kg 200 Aq. Effluent 60 ETP for treatment

5 Water For cleaning Kg 50 Methanol 5 Evaporation loss

Solvent distillation

Residue

70 Recycled

Total Kg 950 Total 950 ----------------

TABLE NO II. POLLUTION LOAD (ALL FIGS. EXCEPT EFFLUENT IN KG)


ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Generated

In

organic

Salt

Organic

Residue

LCOD HCOD Name Qty.

I ------- 570 Nil 798 Nil Nil Nil Nil Nil Nil ---------

A-Pollution load per Month

------- 570 Nil 798 Nil Nil Nil Nil Nil Nil --------


19 Nil 26.60 Nil Nil Nil Nil Nil Nil ---------


Toxic and Hazardous raw materials-

Sulphuric acid

Diethyl amine

Methanol.

No gas of any type is liberated in the process.


Sr.

No.


1 Nil Nil Kg Nil

48

NAME OF PRODUCT

Warfarin Sodium (100 kg/Month)


4-Hydroxy coumarin and Benzyl acetone are condensed in presence of water. The product is

isolated and treated with Toluene and further with IPA and sodium hydroxide to get Warfarin

Sodium.

ROUTE OF SYNTHESIS

.

O

OH

O

+

O

CH3

O

CH3

O

OH

O

4-Hydroxy Cummarin Benzal Acetone

warfarin

O

CH3

O

OH

O

warfarin

O

CH3

O

ONa

O

NaOH

warfarin Sodium n

CH3CH3

O

49


4-Hydroxy Coumarin.

Benzal Acetone

Water

Toluene / Water

Toluene Recovery

Isopropanol/ NaOH

IPA Recovery and recycling

ML recycled

Warfarin Sodium

REACTOR

REACTOR

DRYER

CF

Vacuum Dryer

50

TABLE NO I. STAGE I: - INPUT, OUTPUT AND MASS BALANCE

No Input Name UO

M

Qty. Output name Qty. Remark

1 4-Hydroxy Coumarin Kg 50 Product 60 Final product as warfarin sodium

2 Benzal Acetone Kg 58 IPA 475 Recovered and Recycled

3 Water Kg 400 IPA 25 Fugitive loss

4 Toluene Kg 20 Toluene 15 Recovered and Recycled

5 Isopropanol Kg 500 Toluene 5 Fugitive loss

6 NaOH flakes. Kg 15 Aqueous

effluent

463 HCOD -ETP treatment

Total Kg 1043 Total 1043

TABLE NO II. POLLUTION LOAD (ALL FIGS IN KG EXCEPT EFFLUENT)

Stage

Effluent ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Inorganic

Salt

Organic

Residue LCOD HCOD

I ------- 764 25 Nil Nil Nil Nil Nil Nil Nil


------ ------ 764 25 --------- --------- ------- Nil Nil -------- Nil


------ ------ 25.46 0.83 Nil Nil Nil Nil Nil Nil NIl

1. No pressure or exothermic reaction.

2. No gas evolution during the reaction.

3. Toxic and hazardous raw materials 1. Benzal Acetone 2. Toluene


Sr.

No.


1 Nil kg Nil Nil

51

NAME OF PRODUCT

Metformine Hydrochloride (25.00MT/ Month)


DCDA and DMA HCl is heated in presence of Xylene as solvent. After completion of the

reaction, the reaction mass is cooled and water is charged. Water layer is separated and

carbonized. The carbon is separated by filtration. The product in water layer is separated by

water distillation and methanol addition. The product as metformin hydrochloride is centrifuged

and dried. Methanol is recovered from mother liquor and further processed for II nd

crop

recovery. The water/methanol distilled is send to ETP for treatment. The residue is stored and

sends to HW disposal. [HW –Hazardous Waste].

ROUTE OF SYNTHESIS

NNH2

NH2

NNHCl N NH

2HCl

NHNH

ROUTE OF SYNTHESIS OF METFORMINE HYDROCHLORIDE

+a, b, c

Dycynaodiamide Dimethyl amine Hydrochloride Metformine hydrochloride

Mol Wt 84.05 Mol Wt 81.04 Mpol Wt- 165.05

a. Xylene b.Wtaer C. Carbon

52


Xylene

DMA HCL

DCDA

Water

Carbon

Water Carbon waste for HWS

Methanol

. Distilled water 3200 lit

Metformine Hydrochloride

REACTOR

REACTOR Xylene storage tank. Xylene

is recycled for next Batch

REACTOR

REACTOR

CENTRIFUGE

FLUID BED DRYER

53

TABLE NO I. INPUT/ OUTPUT AND MASS BALANCE

Sr.No Input Output

Remark Name Qty. in Kg Name Qty. in

kg

1 DCDA 500 Product 890 Finished product

2 DMA HCl 525 Distilled water 960 Partly send to ETP and

partially recycled.

3 Water 1200 Distilled Xylene

Xylene

1198

002

Recycled

Fugitive loss

4 Xylene 1200 Methanol 500 Recovery and use

5 Carbon 2 Carbon 2 Sent to MEPL CHWTDS

6 Methanol 800 Effluent HTDS 540 ETP for treatment

7 Hyflow 2 Hyflow 2 CHWTSDF

Methanol 5 Fugitive loss

Process Residue 130 HWTSDF

Total 4229 Total 4229 ----------------------


Stage Effluent in KL

ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Generated

In

organic

Salt

Organic


I 26.88 15.120 100 3640 56 56 -------- ------- ------ ------ -------


26.88 15.120 100 3640 56 56 -------- -------- ------ ---------- ---------


0.896 0.504 3.30 121.33 1.80 1.80 --------- -------- ------- --------- -------


Sr.

No.


------- Nil Kg Nil Nil

54

NAME OF PRODUCT

Flunarizine (1.00MT/Month)


Bis [ 4-Fluorophenyl] Methanone is reacted with methanol and sodium Borohydride to yield .

Di- Phenyl Methanol. The isolated product as stage I is reacted with HCl and heated to 90 degree

and then extracted in ethyl acetate to get the Diphenyl chloro compound as stage II. The stage II

product as chloride is condensed with piperazine to get 1-[Bis(4-Florophenyl) methyl] piperazine

as stage III. Stage III is then condensed with Cinnamyl bromide in acetonitrile as solvent. The

final compound as Flunarizine is extracted in ethyl acetate. Solvent is distilled off to get

Flunarizine final product, which is dried to get dry product.

ROUTE OF SYNTHESIS

55

PROCESS FLOW DIAGRAM - STAGE I

4,4-Difluoro-Benzopheneone

Methanol/ NaBH4

Water /Ethyl acetate Methanol/Water as spent solvent

Sodium Sulfate

Sodium Sulfate for sale

Recovered Ethyl acetate

Mother liquor for recycling

Stage I Product for II stage

[ 4,4-Difluoro Phenyl Methanol]

REACTOR

REACTOR

REACTOR

FILTER

REACTOR

Centrifuge

56

Stage II.

Stage I

Hydrochloric acid

Calcium Chloride

Calcium Chloride for sale

Ethyl acetate

Sodium Sulphate

Rec. Ethyl acetate for recycling

(4, 4 Di fluoro Phenyl Methylene Chloride)

FILTER

REACTOR

FILTER

REACTOR

Centrifuge

REACTOR

57

Stage III.

Stage II

Acetonitrile Recovered Acetonitrile for recycling

Piperazine

Ethyl Acetate

ML for Recycling

4, 4 –Di fluro methyl -piperazine

Centrifuge

REACTOR

58

Stage IV.

Stage III

Acetonitrile

Potassium Carbonate

Cinnamyl Bromide

Potassium Carbonate for sale

Ethyl acetate Rec. Acetonitrile

ML for recycling

FLUNARIZINE

FILTER

REACTOR

Centrifuge

DRYER

REACTOR

59

TABLE NO I: STAGE I: INPUT, OUTPUT AND MASS BALANCE

Sr.No Input Output Remark

Name Qty.

in Kg

Name Qty.

in kg

1 4,4 – Di fluro

Benzophenone

25 Bis[4-Fluorophenyl]-

methanone

24 Stage I product

2 Methanol 250 Spent Solvent 450 Sale to Authorized

recycler

3 Sodium Borohydride 6.50 Ethyl acetate 490 Recovery and use

4 Ethyl acetate 750 Ethyl acetate 1.30 Fugitive loss

5 Sodium Sulphate 25 Sodium Sulphate 25 Sale to authorized

recycler

6 Water 150 Solvent distillation

residue

10 CHWTSDF

Mother liquor 226.20 Recycled for II nd crop

recovery.

Total 1206.5 Total 1206.5

TABLE NO II. STAGE- II. INPUT, OUTPUT AND MASS BALANCE


Name Qty. in

Kg

Name Qty.

in kg

1 4,4 – Difluoro phenyl

methanol

24 4,4’[Chloromethylene]-Bis-

[fluorobenzene]

20 Stage II product

2 HCl 125 Aq. Effluent 144 ETP treatment

3 Calcium chloride 16.70 Ethyl acetate 515 Recovered and used.

4 Ethyl acetate 750 Ethyl acetate 1.7 Fugitive loss

5 Sodium Sulphate 10 Sodium Sulphate 10 Sale to recycler

Mother liquor 235 Recycled

Process organic residue 10 CHWTSDF Disposal

Total 925.70 Total 925.70 -----------

60

TABLE NO III: STAGE III: INPUT, OUTPUT AND MASS BALANCE


Name Qty. in

Kg

Name Qty. in

kg

1 4,4 – Difluoro

pheny methylene

chloride

20 1-[Bis-[4-

fluorophenyl]-

methyl]piperzine

22.20 Stage III product

2 Acetonitrile 200 Acetonitrile 185 Recovery and use

3 Piperzine 7.20 Acetonitrile 1.2 Fugitive loss

4 Ethyl acetate 600 Ethyl acetate 570 Recovery and use

Ethyl acetate 1.50 Fugitive loss

Solvent distillation

residue

47.30 CHWTSDF

Total 827.20 Total 827.20 -------------------

TABLE NO IV: STAGE IV: INPUT, OUTPUT AND MASS BALANCE


Name Qty.

in Kg

Name Qty. in

kg

1 4,4 – Di fluoro phenyl

methyl chloride

20 1-[Bis [ 4-

fluorophenyl]methyl]-

4cinnamylpiperzine

26 Flunarizine Final

product

2 Acetonitrile 200 Potassium Bromide 8.40 Sale to Recycler

3 Potassium Carbonate 19.20 Unreacted Potassium

carbonate

10.80 Sale to recycler

4 Ethyl acetate 400 Acetonitrile 185 Recovery and use

5 Cinnamyl Bromide 9.60 Acetonitrile 1.5 Fugitive loss

6 Carbon/ Hyflo 1/0.5 Ethyl acetate 350 Recovery and use


Mother liquor 65.60 Recycled

Carbon Hyflo 1/ 0.50 CHWTSDF Disposal

Total 650.30 Total 650.3 ------------

61

TABLE NO V: POLLUTION LOAD (ALL THE FIGS. EXCEPT EFFLUENT, IN KG)


ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Generated

In

organic

Salt

Organic


I to

IV

1000 6200 ------- 2365 50 25 ------ -------- ----- 960* 1000


1-IV 1000 6250 ------- 2365 50 25 ------ ------ ---- 960 1000


1-IV 33.30 208.33 ------- 78.83 1.66 0.83 ----- ---------- ---- 32 33.30

*Inorganic salt shall be sold to authorized recycler.


2. No gas is evolved during the reaction.

3. Toxic chemicals used include-HCL, Sodium Borohydride. Cinnamyl Bromide.

62

NAME OF PRODUCT

Moxifloxacin (2.00 MT/Month 33.33 kg/Day)


Cyclopropyl-6, 7- Diflouoro-1.4, Dihydro-4-oxo-3-Quinoline carboxylic acid is condensed with

cis SS 2,8 Di-Azabicyclo –[4,3,0] Nonane in solvent mixture of acetonitrile and Dimethyl form

amide. Catalyst 1,4-Di Azabicyclo [2,2,2] Octane. The resultant product is heated in

hydrochloric acid to get Moxifloxacin Hydrochloride. The crude is converted back to base and

then to hydrochloride using Ethanol as solvent. The wet Moxifloxacin is then dried and packed.

ROUTE OF SYNTHESIS

63


Raw Material I

Raw material II

Acetonitrile / DMF

ML for recovery and use

HCL/ Alcohol

ML for recovery and ETP

MOXIFLOXACIN HYDROCHLORIDE

REACTOR

CF

REACTOR

DRYER

CF

64

TABLE NO I. STAGE I- INPUT, OUTPUT AND MASS BALANCE

Sr. No. Input Output Remark

Name Qty.

in Kg

Name Qty.

in kg

1 Raw Material I 100 Ciprofloxacin HCl 250 Product

2 Raw Material II 190 Acetonitrile 290 Recovery and use

3 Acetonitrile 300 Acetonitrile 0.80 Fugitive loss

4 DMF 50 Acetonitrile in Effluent 9.20 In effluent

5 HCl 100 Ethanol 150 Recovery and use

6 Ethanol 250 Mother liquor 150 Recycled for Base

recovery

7 Water 100 Aqueous effluent 240 ETP for treatment

8 Carbon/ Hyflo 5/2 Carbon / Hyflo 5/2 CHWTSDF-Disposal

Total 1099 Total 1099 --------------------

TABLE NO II. POLLUTION LOAD (ALL THE FIGS EXCEPT EFFLUENT, IN KG)


ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Generated

Inorganic

Salt

Organic


I 1920 -------- ------ ------- 40 16 ------- -------- ----- -------- -----


1929 ------- -------- --------- 40 16 ------- -------- ----- --------- -----


64 ------ ------- ------- 1.33 0.53 ------- --------- ----- --------- ------

1 The reaction is not exothermic. No gas is generated during the reaction.

2 No toxic or hazardous chemicals are used in the reaction.

65

NAME OF PRODUCT

Ketoconazole (1.00 MT/Month)


Cis- Tosylate and N- acetyl -4-[4-hydroxy phenyl]-piperazine are condensed in presence of alkali

as sodium hydroxide using Di methyl sulphoxide as solvent. The reaction mass is cooled and

water is added. The product is extracted in ethyl acetate. The ethyl acetate extract is washed with

water. The water layer is let to ETP for treatment. Solvent ethyl acetate is distilled off completely

and solvent acetone is added. The reaction mass is heated to reflux and carbon is added and

filtered. The filtered reaction mass is cooled and separated product is isolated by centrifuging.

The wet product is washed with methanol. The mL of the product is distilled to recover the

solvent and use. Product is dried to get Ketoconazole.

66

ROUTE OF SYNTHESIS:

67


Cis-Tosylate

Methyl Piperazine

DMSO/ Ethyl acetate

Acetone/Methanol/

Carbon

Water/Ethyl acetate

Acetone

Ethyl acetate Recovery

Methanol


REACTOR

REACTOR SE

.

Aq.Layer to ETP REACTOR

CF

DRYER

68

TABLE NO I. STAGE I- INPUT- OUTPUT AND MASS BALANCE

Sr.

No.

Input Output Remark

Name Qty.

in Kg

Name Qty.

in kg

1 Cis .Tosylate 125 Ketoconazole 110 Product

2 Methyl piperazine 60 Ethyl acetate 630 Recovery and use

3 DMSO 150 Ethyl acetate 1.20 Fugitive loss

4 NaOH Flakes 10.50 Acetone 400 Recovery and use.

5 Sodium Methoxide 14.50 Acetone 1.5 Fugitive loss

6 Ethyl Acetate 900 Carbon 5 CHWTSDF Disposal

7 Acetone 500 Hyflo 2 CHWTSDF Disposal

8 Methanol 100 Solvent distillation

Residue

50

9 Carbon 5 Aqueous Effluent 500 ETP for Treatment.

10 Hyflo 2 1699

11 Water 300 Mother Liquor 168 Recycled for IInd

crop

Total 1867 Total 1867

TABLE NO II. POLLUTION LOAD (ALL THE FIGS. IN KG EXCEPT EFFLUENT)


ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Generated

Inorganic

Salt

Organic


I ----- 4950 ------ 495 50 20 ------ ------- ------ -------- --------


----- 4950 ------ 495 50 20 -------- --------- ------ --------- --------


------ 165 ------ 16.50 1.66 0.66 -------- --------- ------ ------- -----

1. The reaction is not exothermic. No gas is generated during the reaction.

2 .No toxic or hazardous chemicals are used in the reaction.

69

NAME OF PRODUCT

Melatonin (500 kg/Month)


5-Methoxy Tryptophan hydrochloride is dissolved in solvent Dimethyl sulphoxide. Pyridine is

added at ambient temperature. Acetic anhydride is added at ambient temperature and the reaction

mass kept under agitation for 5-6 hrs. at elevated temperature of 50-60 degree. After the

reaction is complete, solvent is distilled off and cold water is added. pH of the reaction mass is

adjusted to 7-7.5 and product is extracted in ethyl acetate. The cumulative extract is washed with

water and the distilled 50% volume. The reaction mass is cooled and centrifuged to get

Melatonin. ML is recycled in the next batch. Wet product is dried and packed.

ROUTE OF SYNTHESIS

70


DMSO

Pyridine

Acetic anhydride

Water/HCl

Ethyl acetate

Aq. layer to ETP

Ethyl acetate recovery

ML recycled

Dry Melatonin

REACTOR

REACTOR

SE

P

REACTOR

CF

DRYER

71

TABLE NO I. STAGE I- INPUT- OUTPUT AND MASS BALANCE

Sr.

No.

Input Output

Remark

Name Qty.

in Kg

Name Qty.

in kg 1 Methoxy Tryptophan 50 Melatonin 40 Final Product.

2 Dimethyl Sulphoxide 150 Spent Ml 299 Sale to Authorized

recycler

3 Pyridine 50 Ethyl acetate 250 Recovery and used

4 Acetic anhydride 50 Solvent distillation

residue

10 CHWTSDF Disposal

5 HCl 15 Ethyl acetate 1.0 Fugitive loss

6 Ethyl acetate 300 Pyridine Recovery 49.50 Sale to authorized

recycler

7 Water 50 Pyridine in spent

solvent

0.50 -----------

8 Carbon/Hyflo 3+2 Carbon/Hyflo 3+2 CHWTSDF Disposal.

Total 655 Total 655

TABLE NO: II. POLLUTION LOAD (ALL THE FIGS IN KG, EXCEPT EFFLUENT)


ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas

Generated

Inorganic

Salt

Organic


I ----- ------- ------- 125 37.50 24 3737.5 ------ ----- -------- ------


------ --------- ------- 125 37.50 24 3737.5 ------- ----- ------- ------


----- ------- ------- 4.10 1.25 0.80 124.58 ------- ------ ---------- --------

1 The reaction is not exothermic. No gas is generated during the reaction.

2 No toxic or hazardous chemicals are used in the reaction.

72

NAME OF PRODUCT

Fluconazole (1.0 MT/MONTH)


1, 3 –Di fluro Benzene is converted to Di fluro 4- Amino 1, 2, 4 Triazole. Which is further

reacted with Trimethyl sulphoxide and plane Triazole to yield Fluconazole. Crude Fluconazole

is crystallized in water to get mono hydrate or anhydrous Fluconazole.

ROUTE OF SYNTHESIS

STEP I

73

STEP II

74


STAGE – I

DFB, Al. Chloride, MDC,

Chloro acetyl Chloride,

Water Aq. Layer to ETP

4-Amino 1, 2, 4 Triazole

Isopropyl Alcohol IPA Recovery and use

HCl, Pot. Carbonate MDC Recovery and use

Sodium Nitrite

Potassium Carbonate

Water

Water for washing Aq. Effluent to ETP

Stage I Fluconazole

`

Reactor

`

Reactor

Reactor

CF

75

STAGE II

Stage I. 2. 1-H, 1,2,4 Triazole.

TMSI, Toluene,

NaOH Flakes,

Water

1, Methylene Di Chloride Aq. layer to ETP

Ethyl acetate

Carbon MDC Recovery and use

MDC Recovery and use

ML for recovery and use

Dry Fluconazole

Reactor

Reactor

Reactor

CF

Dryer

76

TABLE NO I: STAGE: I INPUT, OUTPUT AND MASS BALANCE

Sr.

No.

Input Output

Name Qty. in Kg Name Qty. in kg

1 DFB 60.00 Stage – I Product 100.00

2 Aluminium chloride 70.00 Organic residue 17.36

3 Chloro acetyl chloride 62.00 Alum. chloride sludge 70.00

4 4- Amino 124 Triazole 55.00 Un-reacted chloroacetyl chloride 2.52

5 Methylene chloride 1320.00 Un-reacted Triazole 10.70

6 Isopropyl alcohol 600.00 Methylene Di chloride (recovery) 1056.00

7 sodium nitrite 45.00 Methylene Di chloride (loss) 2640.00

8 Potassium carbonate 54.00 Isopropyl alcohol (recovery) 510.00

9 HCl 100.00 Isopropyl alcohol Evaporation loss 90.00

10 Water 6500.00 Sod. Chloride formed in reaction 38.15

HCl liberated (to scrubber ) 19.21

Potassium carbonate excess 0.30

Potassium Chloride 57.93

Carbon dioxide 17.12

Water formed in reaction with

potassium carbonate

7.00

Water formed in reaction 18.95

Nitrogen liberated in reaction 14.34 14.34

Excess HNO2 escapes which

formed from Na2CO3

5.42

Water from (HCl) 67.00

Water Effluent (HCODS) 1600.00

Water Effluent (LCOD) 4900.00

Total 8866.00 Total 2480.00

77

TABLE NO II:-STAGE II: - INPUT, OUTPUT AND MASS BALANCE

Sr.

No.

Input Output

Name Qty. in Kg Name Qty. in kg

1 Stage – I 60.00 Fluconazole 100.00

2 CS flakes 38.00 Organic residue 17.36

3 TMSI 110.00 Sodium Iodide 67.26 4 1,2,4 – Triazole 33.00 Sodium chloride 26.33

5 Methylene DI

chloride

1200.00 Methylene Di chloride (recovery) 960.00

6 Toluene 80.00 Methylene DI chloride (loss) 240.00

7 Carbon 4.00 DMS formed in reaction 34.97

8 Concentrated HCl 65.00 Excess TMSI Recovered and

recycled.

11.34

9 Ethyl acetate 250.00 Sod. Chloride from Sod. Hydroxide 3.13

10 Water 600.00 Water from excess Sod. Hydroxide 0.95

Water from reaction 8.07

Toluene (recovery) 65.00

Toluene (loss) 15.00

Carbon sludge 4.00

Water from concentrated HCl 43.55

Water from Triazole reaction 8.07

Excess Triazole recovered and

recycled

2.06

Excess HCl in effluent 3.15

Ethyl acetate (recovery) and used 210.00

Ethyl acetate (loss) 40.00

Water effluent to ETP for

treatment

600.00

Total 2480.00 Total 2480.00

78

TABLE NO III: POLLUTION LOAD (ALL FIG. EXCEPT EFFLUENT IN KG)


ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas generated

Inorganic

Salt

Organic


I 9920 30380 1031 Nil Nil Nil Nil CO2

HNO2

HCL

99.90

33.60

119.3

--------- ---------

II ----- 4110 1050 550 25 Nil Nil ----- ----- ------- --------


9920 34490 2081 550 25 Nil Nil CO2 99.90 ------- ------


330.6

6

1149.66 69.36 18.30 0.83 Nil Nil CO2

HNO2

HCl

3.33

1.12

3.97

---------- --------


Toxic and hazardous raw materials- Chloroacetyl chloride, Toluene, Methylene di

Chloride, Aluminum Chloride.

TABLE NO III: - GAS GENERATED OR RELEASED/DAY

Sr. No. Name of the Gas UOM Qty. /Day Remark

1

2.

3

CO2

HNO2

HCL

Kg

Kg

kg

3.33

1.12

3.97

Let to atmosphere

Scrubbed, vent connected to

scrubber.

Scrubbed.

79

NAME OF PRODUCT

Mefenamic Acid (5.O MT/Month)


Ortho Chloro- Benzoic chloride is treated with sodium Carbonate and 2, 3 Xylidine in toluene.

After reaction completion water is added and stirred. Water and toluene layer is separated.

Toluene is distilled to get recovered toluene which is recycled for next batch.

The water layer carbonized and filtered over Hyflo bed. The filtrate is acidified with HCl to

adjust the pH 3-3.5. The precipitated product is centrifuged and then washed with water to a

neutral pH. The product is unloaded and the dried in FBD to get dry Mefenamic Acid.

ROUTE OF SYNTHESIS

80


Toluene

0-Chloro Benzoic acid Water to ETP

Potassium Carbonate

2, 3 Xylidine / Cu Sulphate

DMF / HCl

Water layer to ETP and Toluene layer for Product recovery


Mefenamic Acid

REACTOR

REACTOR

Centrifuge

DRYER

81

TABLE NO I: - INPUT, OUTPUT AND MASS BALANCE

Sr.No Input UOM Qty. Output Qty. Remark

1 0-Chloro Benzoic

acid

Kg 250 Mefenamic Acid 312.5

0

Final Product

2 2,3 Xylidine Kg 220 Toluene 680 Recovered and

Recycled

3 DMF Kg 10 Toluene

Toluene

0.8

12

Fugitive loss

In waste water

4 Sodium Carbonate Kg 220 Solvent Distillation

Residue

18.8 CHWTSDF Disposal.

5 Copper Sulphate Kg 6 Copper Sulphate- 6 In Waste Water

6 30% HCl Kg 100 Carbon 8.0 Send To CHWTSDF

7 Hydrose Kg 5.0 Hyflo 5.0 Send to CHWTSDF

8 Carbon/Hyflo Kg 8.0/5.

0 CO2 Gas 56.90 Let to Atmosphere

9 Water Kg 700 Unreacted Xylidine 62 Recycled.

10 Toluene Kg 700 Waste Water 1077 Send to ETP for

treatment Contains

NaCl and Sodium

Carbonate

Total Kg 2219 Total 2219 ------------



ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Generated

In

organic

Salt

Organic


I 1200 16032 25 300 128 80 -------- -------- ------ ----------- ------


1200 16032 25 300 128 80 ------- --------- ----- -------- ------


40 534.40 0.83 10 4.26 2.66 --------

-

-------- ------ -------- -----

82

NAME OF PRODUCT

Miconazole Nitrate (2.0 MT/Month)


TCAP[ Tri chloro Acetophenone is condensed with imidazole, the resultant product as imidazole

ethanol derivative is isolated and reduced in presence of Sodium borohydride. The product is

isolated and further condensed with Benzoyl chloride. The product is centrifuged and the

converted to Nitrate salt as Miconazole Nitrate in the presence of Toluene and Nitric acid.

ROUTE OF SYNTHESIS

83


Toluene / TCAP/ Imidazole Aq. layer to ETP

Sodium Carbonate /Water

NaOH solution

Methanol/Sodium Boro-hydride Aq. Layer to ETP

Water

Toluene/ Water

Sodium Carbonate Aq. layer to ETP for

treatment

Benzoyl Chloride

Dil. Nitric acid Water /Toluene layer

Water Toluene is distilled and reuse

Water layer to ETP

Water washing Water part to ETP

Toluene Layer for recycling

Miconazole Nitrate

REACTOR

REACTOR

REACTOR

REACTOR

CF

DRYER

84

TABLE NO I:-STAGE I:-INPUT, OUTPUT AND MASS BALANCE

Sr.No. Input Name UOM QTY Output

Name

Qty. Remark

1 Toluene kg 400 Product 90 Imidazole Ethanol

2 Trichloro

Acetopheneone

kg 100 Toluene

Toluene

350

25

Recovery and use

Mitigation loss

3 Imidazole Kg 80 CO2

generated

16.3 Let to atmosphere

4 Sodium

Carbonate

Kg 80 Aq. effluent

HCOD

1228.7 Contains salt NaCl, un-

reacted organics and in-

organics in dissolved state.

5 TBAB kg 10

6 NaOH Flakes kg 2.5

7 Methanol kg 50

8 NaBH4 kg 12.5

9 Water kg 1000

Total kg 1335 Total 1335 ------------------------------

TABLE NO II: STAGE II: INPUT, OUTPUT AND MASS BALANCE

Sr.No. Input Name UOM Qty. Output Name Qty. Remark

1 Toluene kg 400 Miconazole

Nitrate

90 Final product

1 Imidazole kg 90 Toluene 350 Recovery and use

2 Sodium

Carbonate

Kg 100 Toluene 25 Fugitive loss

3 Benzoyl

Chloride

kg 100 Aq. Effluent 750 ETP for treatment

4 Water 500 Organic

Residue

25 HW Disposal

5 HNO3 70 % 50 ------------- ------- --------------------------------

Total kg 1240 Total 1240

85

TABLE NO III:-POLLUTION LOAD (ALL FIG. EXCEPT EFFLUENT IN KG)

Stage

Effluent in lit

ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas

generated

Inorganic

Salt

Organic

Residue

LCOD HCOD Name Qty.

I ----- 40547 ---- ----- Nil Nil Nil CO2 537 Nil Nil

II ---- 24750 500 825 Nil Nil Nil Nil ---------- Nil


----- 62297 500 825 Nil Nil Nil CO2 537 ---------- Nil


----- ----- 2511 19.20 31.70 Nil Nil Nil CO2 20.65 ------------ Nil

No pressure or exothermic Reaction.

Toxic, Hazardous raw material- TCAP, Benzoyl chloride, Sodium Borohydride.

No toxic gas except CO2 is generated in process.

86

NAME OF PRODUCT

Imidazole Ethanol (3.00 MT/month)


TCAPI [Tri Chloro acetophenone] is condensed with imidazole, the resultant product as

imidazole derivative is isolated and reduced in presence of Sodium Boro- hydride. The product is

isolated by centrifuging and dried to get Imidazole Ethanol.

ROUTE OF SYNTHESIS

87


Toluene / TCAP/ Imidazole Aq. layer to ETP

Sodium Carbonate /Water

NaOH solution

Methanol/Sodium Boro-hydride Aq. Layer to ETP

Water


Imidazole Ethanol

REACTOR

REACTOR

CF

DRYER

88

TABLE NO I:-STAGE I:-INPUT, OUTPUT AND MASS BALANCE

Sr.No Input Name UOM Qty. Output

Name

Qty. Remark

1 Toluene kg 400 Product 90 Imidazole Ethanol

1 Trichloro

acetophenone

kg 100 Toluene

Toluene

350

25

Recovery and use

Mitigation loss

2 Imidazole Kg 80 CO2

generated

16.3 Let to atmosphere

3 Sodium

Carbonate

Kg 80 Aq. effluent

HCOD

653.70 Contains salt NaCl, un-

reacted organics and in-

organics in dissolved state.

4 TBAB kg 10

5 NaOH Flakes kg 2.5

6 Methanol kg 50

7 NaBH4 kg 12.5

8 Water kg 400

Total kg 1135 Total 1135 ------------------------------

TABLE NO II:-POLLUTION LOAD (ALL FIG. EXCEPT EFFLUENT IN KG)

Stage

Effluent in lit

ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas

generated

In

organic

Salt

Organic

Residue

LCOD HCOD Name Qty.

I 1500 20000 -------- 100 ------- ------- ------- CO2 825 ---------- --------


1500 20,000 ------- 3.33 ------ -------- -------- CO2 825 -------- ------


----- 50 666 -------- 3.33 ------- ------ ------- CO2 27.50 --------- -------



3. Hazardous raw materials include – Trichloro Acetophenone and Toluene.

89

NAME OF PRODUCT

Mannich Base [Tramadol Intermediate] (2.0MT/Month)


Cyclohexanone and DMA HCl are condensed in presence of HCl at temperature of 100 degree.

After the reaction is over, the reaction mass is cooled and unreacted cyclohexanone is separated.

pH of the reaction mass is adjusted to 10-10.5 and base is extracted in toluene.

The extract in toluene is subjected to distillation till the moisture content of the mass is less than

1%. The reaction mass is cooled and diluted with toluene to get desired % of mannich base. The

aqueous layer is let to ETP for treatment.

SYNTHETIC ROUTE


HCHO/DMA.HCl/Toluene / NaOH Aq. Layer to ETP

Toluene Recovery

Unload in drums

Reactor

Toluene layer

Mannich Base

90

TABLE NO I:-INPUT, OUTPUT AND MASS BALANCE


1 Cyclohexanone Kg 1450 Mannich Base In

Toluene

1300 Stage I in toluene

2 DMA HCl Kg 471 Rec.Cyclohexanone 800 Recycled

3 Formaldehyde Kg 182 Distilled water 600 Recycled in process

4 NaOH lye Kg 570 Effluent- HCOD 970 Treatment to ETP

5 Toluene Kg 1650 Toluene 950 Recovered and recycled

6 Water Kg 800 Toluene loss 15 Evaporation loss

7 HCl 30 % Kg 200 Sodium chloride in

solution

688 ETP sludge

-------- Total kg 5323 Table 5323 -------------------

TABLE NO II:-POLLUTION LOAD (ALL FIGS EXCEPT EFFLUENT IN KG)

Stage

Effluent in

Lit

ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Inorganic

Salt

Organic

Residue

LCOD HCOD

I 300 2610 1800 Nil -------- --------- ------ ---- ------- -------


I 300 2610 1800 Nil ---------- -------- ---------- ------- --------- ----------


I 10 87 60 Nil -------- ------- --------- ------ --------- -----------

1. None of the step is a pressure reaction. No gas is generated at any stage during the

reaction.

2. Toxic/ Hazardous raw materials- Toluene/ Dimethyl amine Hydrochloride.

91

NAME OF PRODUCT

Sodium salt of Phenyl Benz imidazole sulphonic acid (3.00 MT/Month)


3, 4 –Diamino -5- Sulphonic acid is condensed with Benz aldehyde in presence of alkali. After

the reaction the pH of the reaction mass with adjusted with sodium thio Sulphate. The reaction

mass is heated to 60 degree and maintained for 2 hrs. Carbon is added and stirred for ½ hr. The

hot mass is filtered and .pH is adjusted with acetic acid to 3-4.The reaction mass is centrifuged

and washed with water. The product is unloaded and dried to get dry product as sodium salt.

SYNTHETIC ROUTE

92


Diamino Sulphonic acid

Benz aldehyde

Alkali

Carbon / Hyflo

Carbon / Hyflo as HW

Phenyl Benz imidazole sulphonic acid sodium salt

REACTOR

FILTER

REACTOR

Centrifuge

DRYER

93



1 3,4 Diamino

Sulphonic acid

kg 200 Benz imidazole Salt 245 Product

2 Water kg 1250 Aq. Effluent 1257 Waste Water

3 NaOH 50 Lye kg 25 Carbon/Hyflo 8 CHWTSDF

4 Acetic acid kg 25

5 Carbon / Hyflow Kg 5+ 3

6 Sodium

Thiosulphate

Kg 2

Total kg 1510 Total 1510

TABLE NO II:-POLLUTION LOAD (ALL FIGS. EXCEPT EFFLUENT IN KG)

Stage

Effluent in Lit ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Inorganic

Salt

Organic

Residue

LCOD HCOD

I 1000 14000 240 -------- 60 36 ------- ----- --------- ---------


I 1000 14000 240 ------- 60 36 --------- ------- --------- ----------


I 33.33 466.00 8 --------- 2 1.2 --------- -------- ------------ -----------

1. None of the step is a pressure reaction. No gas is generated at any stage during the

reaction.

2. Toxic/ Hazardous raw materials- Toluene/ Dimethyl amine Hydrochloride.

94

NAME OF PRODUCT

Alprazolam (500 kg/Month)


2-Amino -5-ChloroBenzophenone is reacted with Chloro acetyl chloride to give stage I. Stage I

is treated with hexamine and ammonium carbonate using solvent methanol and toluene to give

stage II. Stage II is treated with phosphorus pentasulphide in acetonitrile to give stage III. Stage

III is reacted with acetyl hydrazine to give stage IV. Stage IV is reacted with p-Toluene

sulphonic acid to give stage V. Stage V with hydrazine hydrate gives Alprazolam.

ROUTE OF SYNTHESIS

Stage I

Stage II

95

Stage III

Stage IV

Stage V:

96

PROCESS FLOW DIAGRAM Stage I

Amino Benzophenone

Chloro acetyl chloride

Water/ Acetic acid

Mother Liquor to ETP

Stage I- 2-Chloro Phenyl acetamide

Stage II

Methanol

Stage I

Hexamine

Ammonium Carbonate

Water

Toluene ML for solvent recovery

Stage II-7-Chloro Phenyl Diazepam

REACTOR

Centrifuge

Centrifuge

REACTOR

97

Stage III

Acetonitrile

Stage II

P2S5 / Sodium Carbonate

Water


Aq. ML to ETP

Stage III-7-Chloro -5-Phenyl Diazepine Thione

Stage IV

Stage III

Isopropanol

Acetyl Hydrazine

ML for solvent Recovery

Stage IV- 7-Chloro-5-phenyl-1H-benzo (e) (1, 4) diazepine-2(3H) –thione

Centrifuge

Centrifuge

REACTOR

REACTOR

98

Stage V:

Stage IV

Xylene

PTSA


Methanol

Carbon

Carbon as HW


Alprazolam

REACTOR

FILTER

REACTOR

Centrifuge

FILTER

DRYER

99



1 Amino

Benzophenone

Kg 25 Stage I 31 Product

2 Acetic acid kg 125 Aq. Effluent 469 ETP -treatment

3 CAC kg 15

4 Water kg 350

Total kg 500 Total 500 --------------

TABLE NO II:-INPUT, OUTPUT AND MASS BALANCE


1 Stage I Kg 31 Stage II 22 Product

2 Hexamine kg 58 Methanol 160

3 [NH4]2 CO3 kg 13.6 Methanol 50 Waste Water

4 Methanol kg 210 Aq. Effluent 635.6 ETP treatment

5 Toluene kg 65 Toluene 60 Recovery and use

6 Water kg 550 -------------- ------- ------------------

Total kg 927.60 Total 927.6 -------------

TABLE NO III:-INPUT, OUTPUT AND MASS BALANCE


1 Stage II Kg 22 Stage III 18 Product

2 P2S5 kg 22 Aq. Effluent 125 ETP for Treatment

3 Sodium Carbonate kg 17.60 Acetonitrile 125 Recovery and use

4 Acetonitrile kg 140 Acetonitrile 1.0 Fugitive loss

5 Water kg 100 Organic Residue 32.60 CHWTSDF

Total kg 301.60 Total 301.60 -------------

STAGE IV: TABLE NO IV:-INPUT, OUTPUT AND MASS BALANCE


1 Stage III Kg 18 Stage V 16 Product

2 Isopropanol kg 80 Isopropanol 60 Recovery and use

3 Acetyl Hydrazine kg 14.40 Isopropanol 2.5 Fugitive loss

Organic Residue 33.90 CHWTSDF

Total kg 112.40 Total 112.40 -------------------

100

STAGE V: TABLE NO V:-INPUT, OUTPUT AND MASS BALANCE


1 Stage V Kg 16 Alprazolam 11 Product

2 Xylene Kg 95 Xylene 92 Recovery and use

3 PTSA Kg 0.08 Xylene 1.0 Fugitive loss

4 Methanol Kg 80 Methanol 60 Recovery and use

5 Carbon kg 0.50 Methanol 3 Fugitive loss

-------- --------------------- kg ------- Carbon 0.50 CHWTSDF

Total kg 191.50 Organic Residue 24 CHWTSDF

TABLE NO VI:-POLLUTION LOAD (ALL FIG. EXCEPT EFFLUENT IN KG)

Stage

Effluent in

Lit

ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Inorganic

Salt

Organic

Residue

LCOD HCOD

I 1000 7000 --------- ------- ------ -------- ------ ---- ------- -----------

II 1000 12970 -------- -------- ------- ------- ------- ---- --------- --------

III 500 2875 --------- ------- ------ ------- ---- --------- -------

Iv ------- ------- ------ 915 ------- -------- ------- ----- --------- --------

V -------- --------- ---------- 724 12 -------- ------- ---- ---------- -------

Pollution Load per Month

2500 22845 --------- 1639 12 ------- -------- ---- -------- ---------

Pollution Load per day

83.33 761 -------- 54.60 0.40 ------- ------- ----- ---------- -------

1. The reaction sequence does not involve any pressure or exothermic reaction.

2. No gas is generated during the reaction.

3. Toxic/Hazardous raw material—P2S5, Acetyl Hydrazine.

101

NAME OF PRODUCT

Benfotiamine (200.00 kg/Month)


Thiamine Hydrochloride is reacted with phosphorus acid to get phosphate form of Thiamine

Hydrochloride. This on reaction with Benzoyl chloride in presence of solvent gives Benzoyl

derivative of thiamine. The wet product is isolated by filtration washed and dried to get

Benfotiamine.

ROUTE OF SYNTHESIS

102


Thiamine. HCl

P2O5 / H3PO4

Methanol

Methanol

NaOH

Benzoyl Chloride

Carbon

Carbon as HW, Disposal

Acetic acid

ML for recovery and

BENFOITAMINE

REACTOR

FILTER

REACTOR

.

FILTER

REACTOR

.

Centrifuge

DRYER

103



1 Thiamine HCl kg 25 Benfotiamine 16 Product

2 P2O5 kg 31 Methanol 170 Recovered and used

3 H3PO4 kg 25 Carbon 2 CHWTSDF

4 Methanol kg 300 Hyflo 1 CHWTSDF

5 Carbon Kg 2 Aq. Effluent-

HCOD

479.50 ETP treatment

6 Water kg 250

7 Hyflo kg 1

8 Benzoyl Chloride kg 9.5

9 Caustic Flakes kg 15

10 Acetic acid kg 10

Total kg 668.50 Total 668.50

TABLE NO II:-POLLUTION LOAD (ALL FIGS EXCEPT EFFLUENT IN KG)

Stage

Effluent in

Lit

ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Inorganic

Salt

Organic

Residue LCOD HCOD

I 50 429.50 25 Nil 2 1 ------ ------ ------- --------


6250 53687 3125 ----- 250 125 ------- ----- ---------- ------

Pollution Load per day.

208 1789 104 ----- 8.30 4.16 ------- ----- ---------- --------

104

NAME OF PRODUCT

Tetra Butyl Ammonium Bromide (5.00 MT/Month)


N-Butyl bromide and N- Butyl amine is condensed using acetonitrile as solvent. The product

tetra butyl ammonium bromide is isolated by centrifuging and then crystallized in ethyl acetate.

Both the solvents are distilled and reused. The product is dried and packed.

ROUTE OF SYNTHESIS

105


Acetonitrile

N-Butyl amine

n- Butyl Bromide

Ethyl acetate ML for solvent recovery

Tetra Butyl Ammonium Bromide



1 N- Butyl Bromide kg 2000 TBAB 2500 Product

2 M- butyl Amine kg 1500 Acetonitrile 185 Recovered and use

3 Acetonitrile kg 200 Acetonitrile 1.0 Fugitive and loss

4 Ethyl acetate kg 550 Ethyl Acetate 400 Recovered and use


Ml 1163 Recycled

Total kg 4250 Total 4250 -------------

1. The reaction is solvent based. No water is used. The ML is recycled.


3. Water hardly used for utensil cleaning once in a month or after campaign.

REACTOR

Centrifuge

DRYER

106

NAME OF PRODUCT

4-Chloro-4- hydroxy Benzophenone (2.00 MT/Month)


Phenol is reacted with 4- Chloro Benzoyl chloride using Ortho Di Chloro benzene as solvent and

Aluminum Chloride as catalyst. The resultant reaction mix is quenched in water and stirred. The

reaction mass is settled and solvent layer is separated. The aqueous layer is send to ETP for

treatment. The solvent is distilled to get the product. The recovered solvent is reused for the

successive batches. Product is purified in acetone and toluene.

ROUTE OF SYNTHESIS

107


ODCB / Phenol

AlCl3

4-Chloro Benzoyl Chloride

Water

Aq. layer to ETP

Rec. ODCB for recycling

4-Chloro-4-Hydroxy Benzophenone



1 ODCB Kg 300 Product 175 4-Chloro-4-Hydroxy

Benzophenone

2 AlCl3 Kg 140 ODCB 295 Recovered and used

3 Phenol Kg 94 ODCB 0.5 Fugitive loss

4 4-Chloro Benzoyl

Chloride

Kg 174 Toluene 1190 Recovered and used

5 Water kg 1000 Acetone 135 ML recycled

6 Toluene Kg 1200 Solvent residue 16.50 CHWTSDF

7 Acetone Kg 140 Carbon 2 CHWTSDF

8 Carbon. Kg 2 Aq. Effluent 1140 ETP for treatment

Total Kg 2954 Total 2954

REACTOR

REACTOR

SEPERATOR

REACTOR

108

TABLE NO II: POLLUTION LOAD (ALL FIGS. EXCEPT EFFLUENT IN KG)

Stage

Effluent in Lit

ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas Inorganic

Salt

Organic

Residue LCOD HCOD

I 1140 11856 1596 188 22.80 ----- ----- ---- ---- ----


----- -------- ------ ------- ---------- Pollution Load per day.

38 395.2 53.20 6.26 0.76 -------- -------- ------ -------- ----------

1. The reaction is not exothermic or pressure.

2. No gas in evolved during the reaction.

3. The toxic raw materials—Aluminum Chloride. Benzoyl Chloride.

109

NAME OF PRODUCT

MESALAMINE (5.0 MT/Month)


5-Nitro -2- Chloro benzoic acid is reacted with potassium hydroxide at temperature of 120-125 0C and resultant reaction is centrifuged and acidified to get 4- nitro salicylic acid.

This is when hydrogenated in presence of Raney Ni as catalyst to get 5- Amino Salicylic acid.

Raney Nickel catalyst is isolated and recycled in the process successively.

ROUTE OF SYNTHESIS

110

PROCESS FLOW DIAGRAM:

5-Nitro Chloro Benzoic acid

Potassium Hydroxide

HCl 35 %

Water for washing Acidic water z to ETP

Water, Na2 CO3

Raney Nickel, HCl 35 %

Hydrogen has


Water /HCl/Carbon Raney Ni catalyst for recycling

Solution of sodium carbonate


.

MESLAMINE

REACTOR

CF

Hydrogenator

Pressure-

3.kg/CM2 of H2

CF

FILTER

REACTOR

CF

DRYER

111

TABLE NO I:-STAGE I: INPUT, OUTPUT AND MASS BALANCE [NO OF BATCHES-

92]

Sr.No. Input UOM QTY Output Qty. Remark

1 5 Nitro 2-chloro

Benzoic acid

Kg 100 Product 85 Stage I product

2 Potassium

Hydroxide

kg 140 Aq. mL

[HCOD]

825 Effluent containing

KCL/NaCl as

inorganic salts in

dissolved state

3 Water kg 500 Aq. mL

[LCOD]

300 LCOD effluent ETP

Treatment

4 HCl 30% kg 170

5 Water for

washing

kg 300

Total kg 1210 Total 1210 ---------------

TABLE NO II:-STAGE II: - INPUT, OUTPUT AND MASS BALANCE [NO OF

BATCHES /MONTH 90]

Sr.No. Input UOM Qty. Output Qty. Remark

1 Stage I kg 85 Product 55 Final Product

2 Water kg 640 Catalyst

Raney/Ni

8 Recovered and reuse

3 Na2 CO3 kg 32.6 CO2 generation 20 Let to atmosphere

4 Raney/Ni kg 8.00 Carbon 8.0 HW Disposal

5 Carbon kg 5 Hyflo 5.0 HW Disposal

6 Hyflo kg 3 Effluent 676.6 HCOD ETP

treatment

7 Hydrogen Gas M3 28 Hydrogen 1.0 Released through

water

Total kg 773.6 Total 773.6

112

TABLE NO III: - POLLUTION LOAD

Stage

Effluent in lit

ETP

Sludge

Solvent

Residue

Carbon Hyflo Spent

Solvent

Gas

generated/

Released.

In

organic

Salt

Organic

Residue

LCOD HCOD Name Qty.

I 27600 75900 100 ----- Nil Nil Nil Nil Nil Nil

II ------ 60930 50 ------- 720 450 Nil H2 90kg ---------- Nil


27600 136830 150 ------- 720 450 Nil H2 90 kg Nil Nil


920 4561 5.00 ------- 24 15 Nil H2 3 kg Nil Nil

Pressure reaction with hydrogen in stage II.

Hydrogen pressure is 2-3 kg/cm2 for almost 4-5 hrs.

Hydrogen not consumed is released to air at end of the reaction.

No other toxic gas is generated.

Toxic/Hazardous raw material—Raney Nickel catalyst.

113

THE PLANT WILL HAVE FOLLOWING EQUIPMENT

Sr.No Description/MOC Capacity Qty.

1. Glass Lined Reactor 3.0 Kl 1

2. Glass Lined Reactor 2.0 Kl 1

3. Stainless Still Reactor 2.0 Kl 1




7. Centrifuge 24‖ 1

8. SS Centrifuge 36‖ 1

9. Fluid Bed Dryer 200lit 1

10. SS Sifter 200 kg/Hr. 1

11. Cad Mill 200 kg/Hr. 1

12. AHU I Supply Unit 750 CFM 1

13. AHU II Return air 750 CFM 1

14. Solvent Recovery Unit 100 lit/Hr 1

114

THE LABORATORY WILL HAVE FOLLOWING EQUIPMENT

LIST OF QUALITY CONTROL INSTRUMENTS

S.No. Name of the Instrument Make Model No. ID Number

1. HPLC Waters QC/LC/01

2. GC with Head space Chemito QC/GC/01

3. Head Space GC Agilent Technologies, QC/GC/02

4. FTIR Agilent Technologies QC/IR/02

5.

Karl Fischer Titrator Veego Instruments

corporation QC/KF/01

6.

Melting Point Apparatus Veego Instruments

corporation QC/MA/01

7.

Bulk density apparatus Veego Instruments

corporation QC/BD/01

8. Potentiometric Titrator Spectra Lab QC/PO/02

9.

Automatic Potentiometric

Titrator

Spectra Lab QC/PK/01

10. Analytical Balance Sansui Limited QC/BL/01

11. Analytical Balance A&D QC/BL/02

12. Analytical Balance Sartorius QC/BL/04

13. Hot air Oven Cintex QC/HO/01

14. Hot air Oven Cintex QC/HO/02

15. Muffle Furnace Cintex QC/MF/01

16. UV Cabinet Cintex QC/UV/01

17. Stability chamber Cintex QC/SHC/01


115



21. Magnetic Stirrer Cintex QC/MS/01

22. Sieve Shaker Electrolab QC/SA/01

23. Water Bath (Digital) Cintex QC/WB/01

24. 1 Ultrasonic Bath Cintex QC/AS/01

25.

Heating mantle

(5000ml capacity) Bio technics india QC/HM/01

26.

Heating mantle

(2500ml capacity) Labline QC/HM/02

27. Millipore Water system Millipore Pvt. Ltd. QC/DQ/01

28. Refrigerator Samsung QC/FR/01

29. pH meter Lab India QC/PH/02

30. Remi Centrifuge REMI QC/CF/01

31.

Agilent Cary 60

Spectrophotometer Agilent Technologies QC/UV/02

32.

Head Space GC with auto

sampler

Agilent Technologies QC/GC/03

33. Micro Balance Sartorius QC/BL/05

34. Vacuum oven Cintex QC/VO/01

35.

Dissolution Test

Apparatus

Electrolab QC/DS/01


116

TECHNOLOGY SELECTION

1. The process used is based on Raw materials that are available, without any bottleneck. Thus it

is not necessary to store any one of it in excess, with a fear of crossing expiry date. Excess

storage also means wastage. Here we can follow easily the principle of JIT (Just in Time)

procurement.

2. The process used is developed and streamlined by Yograj Chemicals team and hence are

aware about the sensitive points that need careful attention in advance.

3. The process is cost effective, safe and environment friendly.

4. There is no highly elevated pressure condition in processing.

5. Solvents used are recoverable, and hence recovered and recycled.

6. Working pressure of boiler is reasonably low. Such boilers are available and are easy to

manage.

INSTRUMENTATION

1. Steam flow, feed water flow is measurable (indicating & recording).

2. Water level and liquid material level is measurable (indicating &recording).

3. Multipoint temperature scanner with thermocouple. All points should have indicating &

recording facility for steam, feed water, flue gas and air.

4. O2 analyzer and data logger.

5. Pressure gauges or compound gauges on reactors.

6. Micro-processor based multi-channel data logger to many inputs like current, mv, T/C and

recording with columned dot matrix printer.

7. Micro-processor based hooters for trips, low levels, high levels, and high temperatures.

8. Use of flameproof fittings in manufacturing area.

9. Provision for earthling and jumpers wherever applicable.

117

10. Reaction equipment to be provided with double condenser system and appropriate chilling to

control fugitive emissions.

11. Storage tank provided with flame arrestors.

3.6 RAW MATERIAL AND FINISHED PRODUCTS

RAW MATERIALS

The basic raw material for these products and the details with all reactants, solvents and work

up support chemicals, collectively for the month is given in table of List of products/

Category/Qty. per month & List of raw material for API & intermediate.(Ref. page no.7 to 13)

SOURCE FOR RAW MATERIAL PROCUREMENT

Raw Material is easily available in the local market; some of the raw materials will be procured

from the International Market.

MODE OF TRANSPORT OF RAW MATERIALS

Few of the raw materials will be transported locally and few will be imported (if required) from

the International Market.

STORAGE AT THE SITE

Raw materials will be stored in Storage Yard at the project site. Location of Storage Yard is

demarcated in Layout Plan.

3.7 RESOURCE OPTIMIZATION

Yograj Chemicals is desirous to establish new unit in this sector with 74.70 MT/M product-

sizes. Unit producing synthetic organic chemicals as—

Intermediates for captive consumption and synthetic organic chemicals and (active

pharmaceuticals ingredients) required by various industry.

118

Particulars Proposed

1. Plot Area, Sq. m. 420 Sq. m., 1244 Sq. m.

2. Water input, KLD 59M3/day

3. Fuel Briquette -150kg/hr.

4. 1 no. Boilers, TPH, 750kg/Hr.

5. Stack, m (For Boiler) 30Mtrs

6. Stack, m (DG set) 3.0 Meters

7. HSD for DG set 50.litrs/hr.

8.Coal Nil

9.Briquette 150 kg/hr.

10. Work Force 21

11. Effluent Treatment 20 CMD ETP with RO, Stripper

12. Hazardous waste ------

Used/ spent/ Wastes containing oil 25 kg/day

Distillation Residues and wastes 30 kg/day

Spent catalyst 10 kg/day

Sludge from treatment of waste water 30 Kgs/day

Disposal of barrels/ containers used for

Handling for Hazardous waste / Chemicals

50 Nos/month

Inorganic and MEE Sludge 30 kg/day

Oil & skimming residue 5.0Kgs/ Day

10. Process by Developed by Yograj Chemicals and

hired from the market from the expert

consultants

11. Machinery Available locally

12. Laboratory Sophisticated lab will be established

13. Total Investment 2.5 Crore

3.8 AVAILABILITY OF RESOURCES (WATER, ENERGY/POWER REQUIREMENT)

POWER

Supplied by MSEDCL (MSEB) grid Contract demand – 113 KVA

119

WATER

The water requirement is about 40 m3/ Day for domestic, greenery, and process, and part cooling

purposes. The source of water is already available from existing water works of MIDC and the

same is adequate and satisfactory. The source is dependable and reliable. It does not encroach on

anybody else’s water source.

MANPOWER

The manpower required for administration and production purposes will be recruited locally

without any difficulty. The requirement will be variable as per phase of working but will be

about 21 work- force including staff members, working in shifts.

STEAM REQUIREMENT

Steam requirement for the unit; can be met by using 1 no. boiler of 0.750 TPH. [750 kg/Hr.]

FUEL FOR BOILER

Fuel used will be Briquette (150 kg/hr.)

DG SET

DG Set of capacity 125.00 KVA is proposed for emergency backup. Fuel Requirement will be

50 lit. /hr.)

MATERIAL STORAGE

The R & D will continue its efforts to increase the output, solvent recovery to minimize the input

required for the synthesis and help in minimizing waste generation there by making it

environment friendly.

Measures will be adopted as:

1. Procuring pure raw material and analyzing them before accepting.

2. To reduce inventory by adopting JIT (just in time) procurement.

120

3. Designing the tank roofs to avoid VOC (Volatile Organic Carbon).

4. To go by predictive maintenance rather than preventive or emergency

maintenance.

5. Good housekeeping and machine keeping for enhancing the efficiency

3.9 QUANTITY OF WASTE TO BE GENERATED

Yograj Chemicals proposes to manufacture 74.70 MT/month of Active Pharmaceutical

Ingredients and Synthetic Organic Chemicals or Intermediates. As there is only small quantity of

these 23 products, pollution control work can be much streamlined than a heterogeneous mixed

streams. The details regarding pollution control of water, waste water, air and solid wastes are as

follows:

REUSE/ RECYCLE/ RECOVERY SYSTEMS PROPOSED ALONG WITH DETAILS

Distillation columns shall be installed for the recovery of solvents like Isopropyl Alcohol,

Methanol, Toluene, Formamide and xylene.

The units are equipped with Stainless Steel Reactors; SS packed column, SS Condensers, SS

receivers, SS collection tanks etc. The generated spent solvents shall be collected as Mix Liquor

from Production & will be sending for distillation. The distilled solvents shall be reused for the

reaction. The remaining spent / distillation residue will be send to CHWTSDF. This distillation

activity shall be carried out for minimizing the raw material cost and use if fresh solvent in the

process.

Technical Details:

a) Stainless Steel Reactor:

Capacity – 2 KL (2 Nos.), 1.5 Kl (1 No.)

b) Stainless Steel Column :

Ht. 10.5 mtrs (1 No.). (1, Nos.—Proposed on the additional plot)

c) S.S. Condenser

Area: 10 m2

+ 15 m2

121

WATER & WASTEWATER

The water supply will be through the MIDC. MIDC has provided full water works including

filtration and disinfection. We are not encroaching on anybody’s water source. The water &

wastewater generated in the factory will be as follow.

PROPOSED CHARACTERISTIC OF TRADE EFFLUENT:

A) LOW TDS STREAM

Sr.

No.

Parameter Unit Value

Flow Rate/ Day CMD 155

Design Flow Rate CMD 200

1 pH -- 5.0-8.0

2 COD Mg/ liters 6000-8000

3 BOD Mg/ liters 3000-3500

4 TSS Mg/ liters 800-1000

5 O& G Mg/ liters 10

B) HIGH TDS STREAM

Sr.

No.


Design Flow Rate : CMD 30

1 pH -- 4.0-9.0

2 COD Mg/ liters 25,000- 1,50,000

3 TSS Mg/ liters 100000-150000

4 O& G Mg/ liters 10

C) CHARACTERISTICS OF TREATED EFFLUENT

Sr.

No.


Design Flow Rate : CMD 20 CMD

1 Ph -- 7.0-8.0

2 COD Mg/ liters < 100

3 BOD Mg/ liters <30

4 TSS Mg/ liters <100

5 O& G Mg/ liters <10

122

UNITS AND EQUIPMENT FOR PROPOSED TREATMENT PLANT FOR HIGH TDS

STREAM:

Sr.

No.

Description Size/ Capacity Qty. MOC

1 Collection Tank 2 m3

1 No. SS

2 Feed Pump 1.5 m3/hr. 2 Nos. C.I.

3 Thermo Vapor

Recompressor

Suitable 1 No. S.S.

4 Stripper Column Suitable 1 No. S.S.

5 Preheater 0.2 m Dia. 1 No. S.S.

6 Calendria 0.6 m Dia. 3 Nos. S.S.

7 Recirculation Pump 160 m3/ hr. 3 Nos. S.S.

8 Vapor Liquid Separator 0.6 m dia. x 1.6

m

3 Nos. S.S.

9 Product Pump 1m3/ hr. 3 Nos. S.S.

10 Surface Condenser 0.4 m Dia. 1 No. S.S.

123

UNITS AND EQUIPMENTS FOR PROPOSED EFFLUENT TREATMENT PLANT FOR

LOW TDS STREAM:

Sr.

No.

Treatment Units Sizes Cap(m3) MOC

1 Buffer Tank 2.5 M X 1.5 M X 1.2 M SWD 5 RCC

2 Oil & Grease Trap 2.5 MX1.0 M X1.2 M SWD +0.3

F.B.

4 RCC

3 Equalization Tank 6.0 M X 6.0 M X 3.0 M SWD 108 RCC

4 Primary Settling

Tank

5 M Dia. X 2.5 M SWD +0.3 M

FB Hopper Bottom

(pai xr2xh)= 3.14 x2.5x2.5x2.5

=41.54 = 49.06 = 50

50 RCC

5 Bioreactor- Stage

1

12.8MX12.8M X4.6M SWD +0.5

FB

750 RCC

6 Sec. Clarifier –

Stage -1

5.8 M Dia. X 3.0 M SWD +0.3

FB Hopper Bottom

80 RCC

7 Bioreactor- Stage

2

12.8MX12.8M X4.6M SWD +0.5

FB

750 RCC

8 Sec. Clarifier –

Stage -2

5.8 M Dia. X 3.0 M SWD +0.3

FB Hopper Bottom

80 RCC

10 Intermediate Tank 6.0 M X 1.4 M X 2.5 M SWD 20 RCC

11 Treated Water

Tank

6.0 M X 1.4 M X 2.5 M SWD 20 RCC

12 Sludge Drying

bed- Chemical

5 M X 2M X 1M (2 Nos.) 10 RCC

13 Sludge drying bed-

biological

5 M X 2M X 1M (2 Nos.) 10 RCC

124

Sr.

No.

Treatment Units Sizes HP Qty. MOC

B) Mechanical Work :

1 Belt Skimmer 5 LPH 0.5

Hp

2 Elastomer

2 Alkali Dosing Pump 0-100 LPH 0.5

Hp

2 SS

3 Alum Dosing Pump

for Flash Mixer

0-100 LPH 0.5

Hp

2 PP

4 Alum Dosing Pump

for Secondary system

0-100 LPH 0.5

Hp

2 SS

5 Flash mixer feed

pump

12 m3/ Hr. 3HP 2 PP

6 Primary Sludge pump 1 m3/ Hr. 1HP 2 Roto Pump

SS

7 PSF Feed pump 10 m3/ Hr. 5HP 2 C.I.

9 Air blower for

Equalization Tank

200 m3/ Hr. 10HP 1 C.I.

10 Air Blower for

Bioreactor stage- 1

1800 m3/ Hr. 20HP 1 C.I.

11 Air Blower for

Bioreactor stage- 2

150 m3/ Hr. 10HP 1 C.I.

12 Clarifier Mechanism

for primary Clarifier

3RPH 1HP 1 MS- Epoxy


for Sec. Clarifier –

Stage -2



for Sec. Clarifier –


125

Stage -4

15 Recycle pumps for 2nd

stage Clarifier

12 m3/ Hr. 3HP 2 C.I.

16 Recycle pumps for 4th

stage Clarifier

12 m3/ Hr. 3HP 3 C.I.

17 Pressure sand filter 1.0 M Dia. x2M Height -- 1 MS- Epoxy

18 Activated carbon

Filter

1.0 M Dia. x2M Height -- 2 MS- Epoxy

19 Fine bubble diffuse

aeration System for

Bioreactor stage -1

65 mm Dia. x 2 M

Length

-- 180 Silicon

20 Fine bubble diffuse

aeration System for

Bioreactor stage -2

65 mm Dia. x 2 M

Length

-- 15 Silicon

21 Course bubble mixing

system for

equalization tanks

900 mm long -- 15 PVC

C) Instruments :

Sr.

No.

Instruments Sizes/ Capacity Qty. MOC

1 Magnetic Flow meter 5-20 M3/Hr. 01 PP

2 PH Indicator 0-14 pH 01 PP

3 Pressure gauge Dial Size Lot SS

4 Level Switch for

equalization tank

03 PP

5 Level Switch For

Intermediate Tank

01 PP

126

D) Electrical and piping :

Instruments Sizes/ Capacity Qty. MOC

1 Motor Control Center,

Earthing system, Area

lighting

-- 01 Lot --

2 Interconnecting piping

valves

-- 01 Lot MS & SS

DETAILS OF WASTE WATER TREATMENT PLANT

The Waste Water shall be segregated through two streams

1) High Polluted Stream (HPS)

2) Low Polluted Steam (LPS)

HIGH POLLUTED STREAM

The treatment to the high TDS effluent is given the following sequence.

Stripper Column

Multiple Effect Evaporator

Agitated Thin Film Dryer

The high TDS effluent arising from the production activities are collected in separate collection

tank near plants (HPS Feed Tank).

STRIPPER COLUMN

The continuous stripper system shall be consists of Stripper column, pre heater and condenser as

per the enclosed flow scheme.

The effluent from the feed tank shall be fed to the distillation column after preheating with the

help of vapors in the stripper. The solvent will strip under atmospheric condition. The distillate

from the column shall be discharged by gravity to tank. The bottom of the column shall be

discharge by pump to separate tank.

MULTIPLE (QUADRUPLE) EFFECT EVAPORATOR AND AGITATED THIN FILM

DRYER

The continuous evaporation system will consist of Forced circulation evaporators (FCEs), axial

flow pumps, condensers, vacuum system and Agitated Thin Film Dryer- Vertical (ATFD) as per

the enclosed flow sheet.

127

The feed will be fed from the suitable feed tank to first effect FCE through 2 Nos. pre heaters. In

the first pre heater, feed will be preheated with the help of vapors of the 3rd

effect FCE. In the 2nd

pre heater, feed is further preheated with the help of vapors of ATFD.

In the first effect FCE, water is evaporated with the help of steam on shell side. The mixture of

liquid and vapors will be separate in the separator. The partially concentrated feed from the first

effect FCE then transferred to second, third and fourth effect FCEs respectively to reach the final

concentration. The recirculation is maintained in the FCE in such a way that there is no

evaporation in the tubes. The water will get flashed in the separator and the scaling of the tubes

shall be avoided.

The part of the vapors from the first effect will be transfer to the thermo- compressor where it

will recompress with the help of high pressure steam and used as a heating medium in the first

effect. Remaining part shall be utilized as a heating medium in the second effect. The vapors of

the second effects are utilized as a heating medium in the third effect. The vapors from the third

effect are condensed in suitable cooling water condenser. The concentrated effluent from the

third effects shall be continuously fed to ATFD by a centrifugal pump and the distillate from the

condenser will be discharge with the help of pump. Vacuum in the system is maintained with the

help of water ring vacuum pump.

In ATFD, thin film of liquid shall be form and intensely agitated with the help of rotor. Water is

evaporated by steam on jacket side. The vapors flow counter currently to the pre heater and then

in cooling water condenser and discharged by pump. The solids shall be collected at the bottom

of ATFD. The system is operated at atmospheric pressure. Negative draft shall be maintained by

means of an induced draft blower.

LOW POLLUTED STREAM

For effective bio-degradation of the incoming effluent already designed at 200 CMD capacities

Effluent Treatment Plant will be in use. The processes involved are Equalization &

Neutralization of Hydraulic & Pollution load, Removal of suspended solids through press filter

& Primary sedimentation, Degradation of dissolved pollutants by Biological Treatment through

Activated Sludge Process. Pressure sand filter & Activated Carbon Filter shall be used for

removal of turbidity, color & odour of the treated effluent.

The treatment includes the following:

1) Buffer tank

2) Screening Sump

3) Oil and Grease trap

128

4) Oil Skimmer

5) Equalization cum neutralization tank

6) Acid/Alkali dosing

7) Effluent transfer pump

8) Flash mixture

9) Primary Settling tank

10) Bioreactor –I

11) Secondary settling Tank –I

12) Bioreactor –II

13) Secondary Settling Tank -II

14) Sludge Drying bed

The low TDS effluent generated from the production activities will be collected in separate

collection tank near plants (LPS Tank). The effluent from collection tank is transferred to

screening sump for trapping coarse solids. The coarse solids will be manually skimmed out and

collected in a drum for disposal. The effluent then pump to the oil and grease traps for trapping

oils by virtue of its immiscibility. The oil floats at the surface and shall be skimmed out by using

oil skimmer and collected in drums for disposal. The effluent devoid of oils flows to the

equalization and neutralization tank for equalizing the organic and hydraulic load. Provision of

acid / alkali dosing for neutralization of effluent is made near the tank. The neutralizing agents

will be dosed from the respective dosing tanks. The content of equalization tank shall be mixed

with help of coarse diffused aeration system. The pH is to be intermediately check with the help

of pH indicator till the pH value of 7.5 to 8 is achieved. The equalized and neutralized effluent is

then pumped to flash mixer for primary clarification.

The dosing tanks containing alum are used for coagulant dosing. The flash mixer shall be

provided for mixing the coagulants with effluent. The coagulated mass flows to primary settling

tank for settlement of solids. The primary settling tank shall be provided with the sloping bottom

for effective removal of solids. The clarifier mechanisms will be fitted on the primary clarifier

for effective scraping of the solids from the walls and bottom. The settled solids are drained into

the sludge drying beds for dewatering. The filtrate shall be collected in filtrate collection tank

and pump back to ETP.

BIOLOGICAL TREATMENT

The biological treatment, (Activated Sludge Treatment) consists of following units:

The supernatant from the primary settling tank shall be overflow to aeration tank for the aerobic

treatment. Activated sludge treatment works on the principle of development of microbial culture

in the aeration tank. Each bacterium will be constituted of C, H, N, O and P. The bacteria

assimilate all carbonaceous matter. The oxygen required for the bacterial growth shall be

129

supplied through the silicon membrane diffuser. Air will be supplied to the diffuser through air

blowers. This system is energy saving and effective as compared to surface aerator.

The carbon and hydrogen already present in the effluent. The microbial culture will be developed

in the aeration tank called Mixer Liquor Suspended Solids (M.L.S.S). Mixed Liquor from the

aeration tank will flow by gravity to the settling tank-1. The sludge shall be settled at the hopper

bottom of the Secondary Settling tank – 1. This sludge will be pumped back to aeration tank-1

for marinating M.L.S.S in the tank with the help of Sludge Recycle pump. Excess Sludge from

the settling tank is pumped to the Sludge drying Beds.

The overflow of secondary settling tank-1 shall be flow to aeration tank-2 and overflow of

aeration tank-2 flows to secondary settling tank-2. The organics which will not degraded in the

1st stage bioreactor will be degrade in the 2

nd stage bioreactor. The sludge will be settle at the

hopper bottom of the Secondary Settling tank – 2. This sludge will be pumped back to aeration

tank-2 for marinating M.L.S.S in the tank with the help of Sludge Recycle pump. Excess Sludge

from the settling tank is pumped to the Sludge drying Beds.

TERTIARY TREATMENT

Tertiary treatment includes following units

1. Holding tank

2. Pressure Sand Filter

3. Activated Carbon filter

4. Reverse Osmosis

The biologically treated effluent flows to effluent holding sump from where it is pumped to

pressure sand filter for tertiary treatment. Hypochlorite dosing facility will be provided for

further polishing and disinfection of the treated effluent.

Tertiary treatment consists of pressure Sand Filter and Activated Carbon Filter, which will

remove traced suspended solids which have escaped settlement and dissolved organics, color and

odor. The treated effluent shall be sent for final treatment to reverse osmosis unit. The treated

effluent is used for cooling tower make up and for washings.

The treated effluent shall be recycle and reuse in the process. Industry will achieve Zero Liquid

Discharge.

i. SOLID WASTE

The main solid waste from this factory will be (a) non-hazardous from office, garden and sewage

septic tank and (b) hazardous from process.

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Non-hazardous waste will be segregated as recyclable/ saleable.

Yograj Chemicals has in place the following mitigation policy future:

Waste minimization at all levels for discarded products, empty containers, packing

surplus, unloading spillages and fugitives.

The plant will produce very less amount of scrap material. All these will however be

stored carefully on raised platform, with dwarf toe-walls all around and an overhead roof.

The contents will not be stored in the factory for more than a fortnight.

The main solid waste from factory will be in form of process waste and residues form

solvent recovery. This waste will be transported to CHWTDSF for proper treatment and

ultimate disposal.

The empty drums will be recycled or given back to the original vendors for utilization

The non-hazardous waste will be disposed by scientifically designed composting plant.

[A] NON HAZARDOUS WASTE

Type of Waste Quantity Disposal

Boiler Ash 200 kg/Day To Brick Manufacturer/Cement Industry

Canteen sludge 17 Kg/day To gardening as manure

Packing waste 17 Kg/day To scrap

Office waste 17 Kg/day To scrap

Septic tank sludge 17 Kg/day To gardening as manure

Used spent oil and waste 2 Kg/day To recycling

Polythene bags 10 Kg/day To scrap

HDPE Drums 2 No/day To scrap

MS Drums 2 No/ day To scrap

Cotton waste 3 No/ day To scrap

Broken glass 3 Kg/day To scrap

Corrugated boxes 4 Kg/day To scrap

Paper drums 3 No/day To scrap

MS scrap 3.5 Kg/day To scrap

SS scrap 3.5 Kg/day To scrap

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[B] HAZARDOUS WASTE

Category No Category Qty. kg/Day Disposal

34.10 Flue Gas cleaning,

Residue

5 kg/Day CHWTDSF/Cement

Industry

34.40 Oil and grease

skimming Residue

10 kg/Day CHWTSDF

34.30 Inorganic and ETP

Sludge

167 kg/Day CHWTSDF

33.3 Discarded containers

/Barrels

25 No/Month Sale to authorized Vendor

28.2 Spent catalyst/

Carbon/Hyflo

82 kg/Day CHWTSDF/Cement

Industry

20.3 Distillation Residue 427 kg/Day CHWTSDF/Cement

Industry

20.2 Spent Solvent Qty. generated Sale to authorized

recycler/reprocessor/cement

industry/CHWTSDF

5.1/5.2 Spent oil/Waste and

process Residue

25 kg/Day Sale to authorized

recycler/reprocessor/

CHWTSDF

All the above waste shall be transported to the CHWTSDF /Cement Industry/Authorized vendor

for the proper treatment and finally disposal as ultimate.

METHOD OF DISPOSAL

Collection Reception Storage Transport Treatment Disposal

Y Y Y Y As per the

requirement

Cement industry /Recycler /

Reprocessor

CHWTSDF

132

It may be seen that though the hazardous waste chemicals containers are cleaned and dried.

These cleaned containers / Barrels are stored in separate area and after inspection of Quality

Control Department and after accumulation these waste is sent for disposal through Waste

Management facility.

AESTHETICS

There will be no nuisance from noise. DG set will be run only occasionally. There are no

crushing, pulverizing operations. Labor strength is also limited in this SSI unit. Odour however

can be of some sensitivity in chemical industries. However, in this case majority input is odorless

and only few with mild or characteristics odor. This will be handled carefully. No nuisance will

go to surrounding industries.

133

CHAPTER 04

SITE ANALYSIS

134

4.1 CONNECTIVITY

This proposed Synthetic Organic Chemicals facility is located at existing Industrial Area

Kurkumbh, Daund, in Pune district, Maharashtra. The Site is 75 km from Airport and 6 km from

Daund railway Station. The land and infrastructure is made available by MIDC and the raw

material is easily available through the easy transport via road connectivity. The town has central

state transport station. The site is by the side of National Highway and is only 10 km away. With

all this consideration, this site was ranked first and adopted.

4.2 LAND FORM, LAND USE AND LAND OWNERSHIP

The proposed project is at Plot No, W-28, MIDC E-46/1, E-49, KURKHUMB Tal. Daund, Dist.

Pune, Maharashtra. The Geographical Location of this Industry with an elevation above sea level

(MSL) is as follows.


above sea level

W-28 18.40348109 N 74.53600019 E 615 M

E-49 18.40238418 N 74.53591168 E 612 M

E-46/1 18.40250125 N 74.5363462 E 611 M

GPS Location and Google Imagery of the proposed site are attached as Annexure I.

LAND FORM

Land is on plain contour, it is flat terrain.

LAND OWNERSHIP

Land ownership is with project proponents.

EXISTING LAND USE PATTERN

The Land is reserved for Industrial use. Few Trees are present which will be retained at the site

for Landscape Development.

135

EXISTING INFRASTRUCTURE

Only wire fencing is done. Rest will be done only after getting required consent.

4.3 TOPOGRAPHY

Yograj Chemicals is located on the topographically flat terrain with almost nil undulations. There

is no stream or river passing nearby.

4.4 EXISTING LAND USE PATTERN

Proposed site falls under the Industrial MIDC. The land is reserved for Industrial use.

4.5 EXISTING INFRASTRUCTURE

The only infrastructure provided by MIDC is available. No construction activity has been started

at the designated site. This Project will participate in improvement of the physical infrastructure

of this area.

It will not disturb the existing pattern of drainage, because the building construction is

not massive. It is more of a steel structure not preventing the natural flow of rain

water. There will neither be any inundation nor any erosion. As roof rain harvesting is

proposed, there will not be any incremental run-off causing floods downstream.

Rain water harvesting will improve the groundwater table. On the other hand no

groundwater is consumed by us as we are either dependent on authorized surface

water source or on recycled wastewater after full treatment. The enhanced

groundwater will be indeed useful to the surrounding farmers who are down gradient.

The green crops in their fields on such groundwater will improve the physical

infrastructure.

The industry is dependent on raw materials and chemicals, which arrives by road. The

finished goods will be dispatched by road. All the labor force will come by road.

Thus respective authorities have to maintain the roads in good conditions. Road

136

connectivity thus will improve. This improved physical infrastructure will be an

added facility to the community for surface transport.

When we are developing our own tree plantation, concept of biodiversity will be kept

in mind. This will need many species. These will be made available to us only

through nursery. Nursery once so established will be useful in turn for others

SITE

1. Existing Industrial land, with no encroachment involved.

2. Climatic condition suitable for finer adjustment of control, making it fit for process

condition.

3. Well-connected road/rail network with ease of transportation.

4. Leveled ground and load bearing soil.

4.6 SOIL CLASSIFICATION

The district has three physiographic divisions i.e. (i) Coastal zone in west covers about 20%

percent of the district (ii) Central zone covers about 1/3 rd of the district, consisting of fertile

land in low lying area (iii) Hilly zone in the eastern part highly uneven in altitude and covered

with forest. This hill range is characterized by ruggedness and uneven topography, with crest line

of peaks and saddles forming the eastern horizon. Ulhas, Panvel and Patalganga are the three

main rivers in northern part. Kundalika River is the main river in central part whereas in the

southern part Savitri River is the main river. The soils in the district are formed from the Deccan

Trap which is predominating rock formation with small out crops of Laterite at a few places in

the Poladpur taluka and Matheran hill. The soils are grouped as Forest, Varkas, Rice, Khar or

Saline, Coastal Alluvium and Laterite as per the location and topographical situation.

4.7 CLIMATE DATA FROM SECONDARY SOURCES

Climate and Rainfall The climate of the district is typical of west coast and characterized with

plentiful and regular seasonal rainfall, oppressive weather in summer and moderate humidity

throughout the year. The mean minimum temperature is 17.7°C and means maximum

137

temperature is 33.8°C. The analysis of long term rainfall data indicates that normal annual

rainfall over the district ranges from 300-800 mm. The minimum rainfall is in the northwest

around Daund Indapur (1500 mm) and maximum around Pune (3360 mm).

CLIMATE CLASSIFICATION

Project site features as tropical wet (dry humid) climate under the Koppen climate Classification.

RAINFALL

Most of the rainfall occurs in the monsoon season from June to September. Average annual

rainfall is 1500 mm.

4.8 SOCIAL INFRASTRUCTURE DEMAND:

Infrastructures like Airport are at the distance of 75 Km in North East direction. Central Bus

Stand Daund is at the distance of 10 km in North-West direction. All other social infrastructure

like school, hospital, entertainment places, gardens, library, govt. offices , worship places, etc.

are available in Daund Taluka( which is 9 km from the North West direction ).

138

CHAPTER 05

PLANNING BRIEF

139

5.1 PLANNING BRIEF

M/s Yograj Chemicals (YC) is new entrepreneur and desirous to produce their 23 synthetic

organic chemical and API (Active Pharmaceutical Ingredients) products in this industrial sector.

This unit is at Plot No W-28, E-46/1, E-49, MIDC, Kurkumbh, Daund, Pune, Maharashtra.

FACILITIES

When various sites were seen, this site appeared to be environmentally best as also from the

business angle and therefore this option was finally adopted. This site is inside the existing

MIDC and means safe transportation, less need of Utilities, less constructing buildings and roads,

less fuel, less water with optimization of infrastructure.

Government MIDC has provided all infrastructure like Electrical power, continuous water supply

with purification from water works having RSF (Rapid Sand Filtration) and disinfection, the

internal road network, external approach road, and networking with CHWTSDF (Common

Hazardous Waste Storage Treatment and Disposal Facility) at Ranjangaon vicinity established

with support of MIDC and MPCB.

All surrounding villages are provided with drinking water from wells or Government Water

Supply Schemes RWS. Hence we do not encroach upon their supply.

5.2 POPULATION PROJECTION

Pune district is located in Maharashtra. Population of Pune District is 5,926,606 as per Census

2016. Pune is 2nd

most populous district out of total 35 districts in Maharashtra and is 10th most

populous district in India. The population density of Pune is 5600 persons per square km. it is 8th

most densely populated out of 35 districts in Maharashtra and it is 327th

most densely populated

district out of total 640 districts in India

Total Literacy rate of Pune is 86.15. This means 86.15 out of 100 persons of age more than years

are literate. It is ranked in terms of literacy rate out of total 35 districts of Maharashtra and 10th

out of total 640 districts of India. Male literacy of Pune is 90.84% while female literacy stands at

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81.05%. Sex ratio of Pune is 948 female per thousand male. Area of Pune is 15642 Sq. km. it is

2nd

largest district in Maharashtra and 126th largest in India in terms of total area.

District Pune

State Maharashtra

Population 5,926,606[ 2016]

Population Density 5600/ Persons/Sq. Km

Male Population 4924105 [Census 2011]

Female Population 4,505303 [ Census 2011]

Sex Ratio 948

Total Literacy rate 86.15%

Mail Literacy rate 90.84

Female Literacy rate 81.05

Area sq mile. 6039

5.3 LAND USE PLANNING

The proposed project is in Government MIDC Industrial area and is not a prime Agricultural

Land. The land-use is already as ―Industrial area‖. Thus there is no change in the status. This is

flat and Hilly land whereby Cutting-filling balances and there will be No/Low Borrowing from

nature. Topography Map of the proposed site is attached as (Annexure IV).

Expansion and 33% area will be demarcated for Green belt development.

141

5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND (PHYSICAL AND SOCIAL)

Yograj Chemicals proposed new project will be having only production of Synthetic Organic

Chemicals/ API at small scale; which does not require any additional existing Physical

Infrastructure; so there will not be any demand of expansion of physical infrastructure and social

infrastructure. As manpower requirement is very less for the proposed project that will not lead

to any additional load on the existing social infrastructure.

5.5 AMENITIES/ FACILITIES

Yograj Chemicals is proposing Synthetic Organic Chemical products in MIDC. MIDC provides

many basic facilities like uninterrupted water supply, power and Road Network & solids disposal

facility if feasible. This site is inside the campus of the MIDC and means safe transportation, less

need of Utilities, less constructing buildings and roads, less fuel, less water with optimization of

infrastructure and networking with CHWSTDF (Common Hazardous Waste Storage Treatment

and Disposal Facility) at Ranjangaon, Pune, (Maharashtra).

142

CHAPTER 06

PROPOSED

INFRASTRUCTURE

143

6.1 INDUSTRIAL AREA

There will be only Processing Area in this proposed project. Yograj Chemicals proposes to

manufacture Synthetic Organic Chemicals & Intermediates having production capacity 74.70

MT/Month.

6.2 RESIDENTIAL AREA

In Yograj Chemicals no Residential area has been proposed for the proposed project. Facility

will be provided for emergency workers only, but no one will stay in the premises.

6.3 GREEN BELT

About 33% of the total Plot area shall be proposed for tree plantation. The selection of trees shall

be based upon tolerance to treated effluent.

In and around the Yograj Chemicals project plantation shall be carried out to develop green belt.

The treated effluent is used for green belt development within the factory premises. Partially and

send to CETP for further treatment.

Following shall be the status of green belt development.

Suggested List of Species for landscape development:

Sr. No. Name of Plant Common Name

For Dry Region

1 Ailanthus excelsa Maharuhk

2 Albizia lebbeck Siris

3 Azadiracta indica Neem

4 Casuarina equisetifolia Beef- wood

5 Dalbergia sissoo Sisham

6 Eugenia jambolana Jamun

7 Grevillea robusta Silver oak

8 Peltophorum ferrugineum Copper pod

9 Tamarindus indica Imli

10 Pongamia glabra Indian beech

11 Tamarix articulate Tamarisk

12 Mangifera indica Mango

13 Ficus glomerata Umbar

14 Ficus bengalensis Vad

144

15 Dandrocalamus strictus Cane Bamboo

16 Cassia tora Tarwat

17 Bauhinia varigeta Kanchan

18 Psydium guava Peru

19 Plumbago zeylania Plumbago

20 Santalum album Chandan

21 Acalypha spp. Acalypha

22 Alastonia scolarasis Saptaparni

23 Embelica officinalis Amla

24 Hibiscus spp. Jaswand

25 Jatropha curcus Mogli errand

26 Sympogon martini Lamon grass

27 Lantana camara Lantana

28 Vinca rosea Sadafuli

29 Jasmine grandiflorum Jasmine

30 Calotropis procera Aak

31 Ipomea purpurea Beshram

32 Dhatura mental Dhatura

33 Vitex nurgundo Nirgudi

34 Ixora parviflora Ixora

6.4 SOCIAL INFRASTRUCTURE

In Yogiraj Chemicals, there is no need of providing any Social infrastructure as the proposed

project is involving only very small number of man power. Existing infrastructure will be

sufficient to accommodate the increasing load from the proposed project.

6.5 CONNECTIVITY

This proposed Synthetic Organic Chemicals facility is located at MIDC Kurkumbh, in Pune

district, Maharashtra. The Site is 75 km from Pune airport and 9 km from Daund railway Station.

The land and infrastructure is made available by MIDC and the raw material is easily available

through the easy transport via road connectivity. The site is by the side of National Sholapur

Highway is at the distance of 2 km in North West. With all this consideration, this site was

ranked first and adopted.

145

6.6 DRINKING/ INDUSTRIAL WATER MANAGEMENT

The water requirement is about 59 M3 /day for Domestic, Greenery and processes. The source of

water is already availability from existing water works of MIDC and the same is adequate and

satisfactory. We are not encroaching on anybody’s water source.

6.7 SEWAGE SYSTEM

Yograj Chemicals will propose ETP plant according to their requirement for proposed

production Capacity of 74.70 MT/Month of Synthetic Organic Chemicals. The Domestic

Effluent will be treated in Septic Tank and will be used for green belt development.

6.8 INDUSTRIAL WASTE MANAGEMENT

Yograj Chemicals proposes only 74.70 MT/Month Synthetic Organic Chemicals manufacturing.

And as there are only- 23 products, pollution control work can be much streamlined than a

heterogeneous mixed stream. The details regarding pollution control of water, waste water, air

and solid wastes are as follows:

AIR POLLUTION

The air pollution caused by this industry is mainly from emission from production process and

DG set .The DG set shall be provided with self-supporting stack with acoustic enclosure

followed by stack of 30 Meter. in height.

Process emission: - Acid fumes SO2, Ammonia and traces of HCl will be eliminated during

process. The gases will be scrubbed 2 stage scrubber .Water scrubber following alkali solution

scrubber. Traces of ammonia, acid and HCl shall be absorbed in scrubber.

FUGITIVE EMISSION

A number of mitigation measures are taken to control fugitive emission, the presence of which

will be noticeable by plain vision, if not controlled. The measures are set thus taken seriously and

continuously such as

146

1. Rubber wheel carts /Trucks to bring in raw not filled high, sides cladded slow speed

travel avoiding vibration enroot.

2. Collection of fugitive emission by suitable suction system at the time of charging.

3. Engineering the plant layout in such a way so as to virtually eliminate need of using

heavy equipment for material handling in the main plant.

4. Internal roads paved, scrap area paved, leveled, no undulation no sharp curves, slow

speed. No open storage of materials on barren unlined land to the maximum extent

possible.

6.9 SOLID WASTE MANAGEMENT

The main solid waste from this factory will be

(A) Non-hazardous from office, garden and sewage septic tank and

(B) Hazardous from process.

Non-hazardous will be segregated as recyclable/ saleable. This will be so done. Yograj

Chemicals will have in place the following mitigation policy in future:

Waste minimization at all levels for discarded products, empty containers, packing surplus,

unloading spillages and fugitives.

The plant will produce very less amount of scrap material. All these will however be stored

carefully on raised platform, with dwarf toe-walls all around and an overhead roof. The

contents will not be stored in the factory for more than a fortnight.

The main solid waste from factory will be in form of process waste and residues form

solvent recovery. This waste will be transported to CHWTDSF for proper treatment and

ultimate disposal.

The empty drums will be recycled or given back to the original vendors for utilization.

The non-hazardous waste will be disposed by scientifically designed composting plant

147

(a) NON HAZARDOUS SOLID WASTE

i) FROM PROCESS MANUFACTURE

The quantity of generation of fuel as generated in Boiler which will be sent to brick mfg.

industry/ cement industry.

ii) FROM THE WASTE TREATMENT

The generated solid waste from the Effluent Treatment Plant is mostly containing dried

Biomass. This Biomass will be mixed with Domestic Bio waste (dry leaves, roots & hey)

& composting will be carried out for producing bio-compost & will be used for Green

Belt Development.

iii) TREATMENT It will be used as compost.

(b) HAZARDOUS WASTE

The quantification of solid waste generated from the factory can be presented as follows:

Category

no.

Category Qty. Kg/Day Disposal

5.1/5.2 Spent Oil/waste &

process residue

containing oil

25 Kg/Month Authorized recycler/ re

processor /CHWTSDF

20.2 Spent solvents As per generation Sale to authorized recycler/

preprocessor/Cement

Industry/CHWTSDF

20.3 Distillation Residue 40 Kg/Day Cement Industry/CHWTSDF

28.2 Spent Catalyst/Spent

Carbon

100 Kg/Month Cement Industry/CHWTSDF

33.3 Discarded

Containers/Barrels/

Liners

50 Nos. / Month Sale to authorized vendor

34.3 Sludge from Waste

Water TREATMET

300 Kg/Month Cement Industry/ CHWTSDF

34.3 Inorganic , Sludge 300 Kg/Month Cement industry/CHWTSDF

34.4 Oil & Grease

skimming Residue

50 Kg/Month CHWTSDF

34.1 Flue gas cleaning

residue, boiler soot

20 Kg/Month Cement Industry/CHWTSDF

All the above waste will be transported to the CHWTDSF/Cement Industry/Authorized Vendor

for proper treatment and ultimate disposal.

148

METHOD OF DISPOSAL

Collection Reception Storage Transport Treatment Disposal

Y N Y Y As on

requirement

Cement

Industries/CHWTSDF/Authorized

recyclers/reprocessors

It may be seen that though the hazardous waste chemicals are cleaned and dried. These cleaned

containers / Barrels are stored in separate area and after visual inspection of Quality Control

Department and after accumulation these waste is sent for disposal through Waste Management

facility.

6.10 POWER REQUIREMENT AND SUPPLY/SOURCE

Yograj Chemicals power requirement is 115 KW available through MSEDCL. DG set of 125

KVA is proposed for emergency backup. Qty. of fuel [HSD] shall be 50 Lit / Hr. [Applicable

only in emergency].

WATER CONSUMPTION & WASTEWATER

The water supply will be through the MIDC. MIDC has provided full water works including

filtration and disinfection. We are not encroaching on anybody’s water source. The water

consumption & wastewater generated in the factory will be as follows:

WATER BUDGET

Phase Water (CMD) Effluent (CMD)

Consumption Losses Domestic Industrial

Domestic 2.00 0.5 1.50 -----

Industrial Cooling 10.00 8.0(Wind age loss) ---- 2.0

149

Boiler Feed 12.00 2.00(Evaporation) ----- 10.00

Industrial

Processing/Washing

30.00 2.0(Mixing in R.M. and

evaporation loss)

---- 28

Gardening 5.00 5.00 Nil Nil

Total 59 17.50 1.5 40

The Effluent from the factory shall pass through HDPE pipelines and shall collect by gravity to

bull storage tank. It will be neutralized and then transferred to plot E-46/1, E-49 for further

treatment.

An ETP shall consist of:

1. Screen Chamber

2. Solvent Trap

3. Equalization cum Neutralization Tank

4. Primary Treatment with Chemical Oxidation

5. First stage aeration and first stage Clarifier followed by secondary stage aeration and

secondary stage clarifier.

6. The treated water after secondary stage clarifier shall be passed through tertiary treatment

comprising of Pressure Sand filter and Activated Carbon Filter.

7. Sludge drying beds shall be provided for drying of sludge from Primary and Secondary

Clarifier.

8. The treated water after tertiary treatment shall be used for processing.

150

CHAPTER 07

REHABILITATION

AND

RESETTLEMENT

(R & R PLAN) Not applicable for the awarded site as it approved. More than 100 units are functioning.

151

CHAPTER 08

PROJECT

SCHEDULE & COST

ESTIMATES

152

8.1 TIME SCHEDULE OF THE PROJECT

HFL has ability to complete their construction within 2 to 5 Months after getting all relevant

permissions and clearances.

8.2 ESTIMATED PROJECT COST (ECONOMIC VIABILITY OF THE PROJECT)

Estimated project cost is to 1.5 Crore

EMP Cost is 5 Lakh.

153

CHAPTER 09

ANALYSIS OF

PROPOSAL

154

9.1 FINANCIAL AND SOCIAL BENEFITS

HFL has proposed to develop Synthetic Organic Chemicals products which will be used for

curing of different diseases in social community and help to maintain healthy life. This support

needs to control human diseases and disorders. This will be an important substitute for local

market and also useful for defense services.

Some of the Medicines are available only in the international Market, which are very costly and

are not available to the local people. To overcome this situation HFL purposes to manufacture

such drugs that can be made available at lower rates to local community.

By doing this HFL can help the nation in saving the foreign exchange and also serve the social

community. Day by day population is increasing and in similar way the requirement of the basic

needs like Medicines, which are very essential for everyone is also increasing and there is a need

to supply required medicines at an affordable price.

Due to the change in lifestyle & simultaneously increasing population newer ailments & diseases

are prevailing. For these new ailments demand of medicines is increasing. To cope up with the

incasing demand, we are introducing new molecules, so that the demand & supply gap can be

filled. With the introduction of new products, cost of these products will be more economically

viable.

ANNEXURE I

Google Earth Imagery depicting location of M/S YOGIRAJ CHEMICALS at Kurkumbh, MIDC

with coordinates.

ANNEXURE II

Toposheet of Study Area

ANNEXURE III

Proposed Master Layout on Plot W-28, E-46/1, E-49

ANNEXURE IV

MIDC Layout

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ANNEXURE V

Summary of pollution load.

Documents

M/s. Yograj Chemicals , W-28, MIDC, KURKHUMB, …environmentclearance.nic.in/writereaddata/FormB/TOR/PFR/01_Nov... · generally allocated to this account head in every annual budget