1. introduction - welcome to...

Pre-Feasibility Report Sri krishna Pharmaceuticals Limited, Unit-III

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1. Introduction

M/s. Sri Krishna Pharmaceuticals Limited, Unit-III (Formerly Sri Krishna

Drugs Limited) was established in the year 1988. It is located at Sy. No.

57, Golkonda kalan, Raikunta (V), shamshabad (M), Rangareddy (D),

Telangana state .

The unit obtained NOC (CFE) of A.P. Pollution control Board in the year

1988 and started operations.

The Ministry of Environment and Forests accorded Environmental

Clearance to the industry vide Environmental Clearance File No: J-

11011/147/2005-IA.II(I) Dt: August 11,2005 to manufacture folic acid

with a capacity of 96.0 TPA. Copy of Environmental clearance is enclosed

as Annexure I. The unit obtained CFE for Change of Product mix vide

order No. APPCB/HYD/KTN/311/CFE/HO/2009 dated 25.06.2010 and also

vide order No. 311/TSPCB/CFE/RO-RR-I/HO/2014-1262 dated

20.03.2015. Copy of latest CFE is enclosed as Annexure II.

Subsequently obtained CFO of the Board vide letter No.

APPCB/10017/ZO-HYD/ HO/CFO/2014-112 dated 04.04.2014 with a total

capacity of 8.0 TPM. Current CFO Copy is enclosed as Annexure III

In order to meet the market demand it is now proposed to expand the

production capacity from 96.0 TPA to 589.4 TPA.

Applied for Certified Copy of Compliance Report from MoEF & CC,

Government of India, Chennai Regional Office is enclosed at Annexure- IV


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2. Introduction of the Project

The salient features of the project are described in the table given below

TABLE 1.0

Salient Features of the Project

Location Sy. No. 57, Golkonda kalan, Raikunta (V),

shamshabad (M), Rangareddy (D), Telangana

Longitude and Latitude 17o11’58.6’’ N & 17o12’04.6’’ N Latitude 78o25’08.8’’ E & 78o25’18.3’’ E Longitude

Year of Establishment 1988

Product Category 5(F) Bulk Drugs & Intermediates

Project Category as per EIA notification

“A” ( Not in notified Industrial Estate)

Proposed Activity Capacity expansion from 96.0 TPA to 589.4 TPA

Total investment on the plant Current - Rs. 31.85 Crores & Proposed – Rs.40.0 Crores

Total Investment on Environmental Infrastructure

Rs. 5.0 Crores (Current) Rs. 10.00 Crores ( Proposed)

Total area of the plant 12.0 Acres

Total area of green belt 5.0 Acres

Water requirement Total water requirement after expansion 802.30 KLD

Fresh water requirement 552.3 KLD Recycled water 250.0 KLD

Source of water Borewell Nearest habitation and distance from the site

Bahadurguda -1.71 Km

Nearest surface water bodies Rainfed water tank at a distance of 0.78

Km from site

Nearest reserve forest Nearest Reserve forest is at a distance of

1.4 km.

Environmentally sensitive areas

within 10 km radius None

Any national parks, wild life

sanctuaries within 10 km radius None

Nearest air port and distance Shamshabad, RGI-3 Km

Nearest railway station and distance

Umdanagar-7.43 Km


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i) Introduction of the company and proponent

Sri Krishna Pharmaceuticals Limited, unit-III (Formerly Sri Krishna Drugs

Limited) was incorporated as a public limited company under the

Companies Act, 1956 at Hyderabad in the state of Andhra Pradesh, India

during the year 1988. The company is engaged in the manufacturing of

Active Pharmaceutical Ingredients (APIs) and API Intermediates for

catering to the domestic as well as international market.

The company recognized the vital role of R & D for becoming successful in

the generic market.

About Proponent

The management at Sri Krishna Pharmaceuticals Limited, Unit-III

(Formerly Sri Krishna Drugs Limited) consists of highly qualified and richly

experienced persons who have given the company the edge in terms of

quality, consistency, timely delivery and ability.

The company is headed by Mr. V. V Krishna Reddy, Managing Director,

having vast experience in various businesses.

About the Unit

Sri Krishna Pharmaceuticals Limited established this manufacturing unit in

the year 1988 and obtained Environmental Clearance from Ministry of

Environment with a capacity to manufacture Bulk Drugs with a capacity of

96.0 TPA.

Quality Management: Strict quality control measures, Good

Manufacturing Practices (GMP) are integrated throughout the

manufacturing process to ensure strict adherence to the quality

parameters for both in-process and finished products.


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3. Project Description

3.1 Production Capacity

Currently the unit is permitted to manufacture 11 drugs out of which 4

are regular products and 7 are campaign products (any 3 products can be

manufactured at a given point of time) with a total capacity of 8.0 TPM as

detailed below

TABLE 2.0

LIST OF EXISTING PRODUCTS

S.No Name of the Products Quantity in TPM

Regular Products

1 Folic acid pharma 4.0

2 Metadoxine 0.50

3 Fenoverine 0.30

4 Tiemonium methyl sulphate 1.20

Campaign Products( Group B) an three products at a time

5 Doxylamine succinate 0.250

6 Enalapril Maleate 0.750

7 Iso Metheptene Mucate 0.5

8 Phenylephrine Hydrochloride 0.750

9 Meclazine Hydrochloride 0.50

10 Sodium Phenyl Butyrate 0.350

11 Butrorphanol Tartrate 0.02

Total ( Worst combination) 8.0

3.1.1 Proposed expansion:

It is now proposed to expand the production capacity of the existing 1

product and to manufacture all the existing products. Below Table

provides list of products and proposed capacities.


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TABLE 3.0

PROPOSED PRODUCTS & CAPACITY

S.No Name of the Products Quantity in TPM

1 Folic acid pharma 44.0

2 Metadoxine 0.50

3 Fenoverine 0.30

4 Tiemonium methyl sulphate 1.20

5 Doxylamine succinate 0.250

6 Enalapril Maleate 0.750

7 Iso Metheptene Mucate 0.5

8 Phenylephrine Hydrochloride 0.75

9 Meclazine Hydrochloride 0.50

10 Sodium Phenyl Butyrate 0.350

11 Butrorphanol Tartrate 0.02

Total 49.12

3.2 Manufacturing Process

Brief process description and process flow charts are given at Annexure

VI

3.3 Raw Materials

List of raw material product wise is given at Annexure V

3.4 Water Requirement

The water requirement will be met Ground water. The requirement for

water in this unit is for process and domestic purposes. The water balance

for daily consumption is presented below.


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TABLE 4.0

Water Balance– Current & Proposed

S.

No Stream

Water requirement in KLD

Waste Water discharge in KLD

Proposed Method of

Treatment and Disposal

Current

After

Expansion Current

After

Expansion

1 Process

52.5

346.8

55.387

369.9

Stripper, MEE and ATFD

(Condensate to RO)

2 Washings

3.0 3.0

Stripper, MEE

and ATFD (Condensate to

RO)

3 Scrubbers 2.0 4.00 2.0 4.0

Stripper, MEE

and ATFD

(Condensate to RO)

4 Boiler 17.5 117.5 2.5 12.5

ETP followed by RO ( RO Reject

to MEE)

5 DM/Softener -- 3.0 -- 3.0

ETP followed by RO ( RO Reject

to MEE)

6 Cooling &

Regeneration 40.0 244.0 10.0 34.0

ETP followed by

RO ( Ro Reject to MEE)

7 Domestic 18.0 54.0 8.0 33.0

ETP followed by RO ( Ro Reject

to MEE)

8 Gardening 30.0 30.0 -- --

Total 160.0 802.3 77.88 459.4

3.5 Wastes generation and control systems

3.5.1 Liquid Effluents

As detailed in Table 4.0 waste water generation after expansion would be

459.4 KLD. It is proposed to segregate effluents into high COD and High

TDS stream and Low COD and Low TDS streams.


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High TDS and High COD stream would be treated in stripper followed by

MEE and ATFD. The resultant sludge would be disposed to TSDF,

Hyderabad. The Low TDS stream would be treated along with MEE/ATFD

condensates in biological ETP followed by RO. The RO rejects would be fed

back to MEE. The Permeate from RO would be used for cooling tower

make up. Thus the treatment system proposed is based on “Zero Liquid

Discharge” (ZLD) Concept

The schematic diagrams of ETP proposed are given in Figure 1.1 and

Figure 1.2 below


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Fig 1.1 Schematic Treatment Scheme of High TDS Effluents

Effluent from Process and Aq. Distillate to

Cement Plant/TSDF Recovery Washings, Scrubber

RO Reject To TSDF Condensate to Biological Treatment Condensate to Biological Treatment

Sludge to TSDF

Equalization

Tank

MEE

ATFD

Stripper

Neutralization

Tank

Settling

Tank


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Fig 1.2 Low TDS Effluent Treatment System

Domestic effluent

Effluents from utilities & MEE condensate

Sludge to TSDF

Permeate for re-use

Rejects to MEE

Screen

Chamber

Sludge Holding Tank

Aeration

Tank2

Equalization

Tank

Neutralization

Tank

Clarifier

2

Holding

Tank

Filter Press Sludge Cake

Aeration

Tank1 Clarifier

1

Sand

filter

Carbon

Filter

Ultra

filtration RO

Screen

Chamber


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3.5.2 Solid wastes management

Hazardous and non - hazardous wastes generated from the proposed

expansion project are detailed below. Mode of disposal are also identified

and listed. Adequate storage of hazardous waste is ensured at the site

TABLE 5.0

Solid Wastes and Disposal

S.N

o Description

Quantity

Remarks Current

TPM

After

Expansion TPM

1

MEE salts/ Gypsum/

Calcium Chloride equivalent salts

93.332

593.33*

Sent to TSDF, Dundigal

2 Inorganic salts -- 13.15 Sent to TSDF, Dundigal

3

Distillation bottom

Residue/In soluble organic

residue

3.887 5.46

Authorized cement plants for co-

processing/ TSDF, Dundigal

4 Spent carbon 0.157 0.21

5 ETP sludge -- 9.0 Sent to TSDF, Dundigal

6 Iron sludge 4.758 52.28

Authorized cement Industries

7 Spent Nickel 0.08 0.80

For re-processing

Total 102.214 674.23

8 Boiler Ash -- 600.0

Sold to brick manufacturers

9 Waste oil 70.0 LPM 100.00 Authorized recyclers/ re-

processors

10

Detoxified

Container and container liners

50 No’s/Month

100.00

After complete detoxification it

shall be disposed to the outside agencies


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Of hazardous waste chemicals

11 Used lead acid batteries

10 Nos/Year

10.00 Authorized recyclers on buy back basis

12 Spent solvents 10 KL/

month 20.00kl/month

To authorized recyclers/cement industries for co-Processing

*Includes salts from MEE and Neutralization salts.

TSDF facility is about 70 KM from the site in Rangareddy District which is

created for catering the industries in this area. Transport of Hazardous

wastes to TSDF is done by the Ramky. In case other hazardous wastes,

authorized recyclers will transport the wastes

4. Site Analysis

4.1 Plant Location

M/S Sri Krishna Pharmaceuticals Limited, unit-III Sy. No. 57, Golkonda

kalan, Raikunta (V), shamshabad (M), Rangareddy (D), Telangana state.

The site is situated at 17o11’58.6” N and 17o12’04.6” N Latitude and

78o25’08.8” E and 78o25’18.3” E Longitude. The land area of the plant is

11.3 acres. The nearest habitation from the site is bahadurguda (V) at a

distance of 1.71 km. The nearest railway station located at Umdanagarat

7.43 KM from the Plant. There are no ecologically sensitive areas like

national parks, sanctuaries within 10 km radius of the site.

Following are the surroundings of the site

North – Private lands

South –Approach road followed by industry’s own land with guest

house

East – Private lands

West - Outer ring road


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Following 9 reserve Forests are there within 10 KM radius of the site

Table 6.0

Reserve Forests in the study area

S.No Reserve Forest Direction from the

site

Distance from the

site (KM)

1 RF E 1.4

2 RF S 2.0

3 Maisaram SE 5.5

4 Lemur SE 5.8

5 Kongarkala SE 9.6

6 Jallapalli NE 9.6

7 Domnair NW 9.7

8 RF W 5.0

9 RF NE 3.7

Topo graphic features of the site and 10 KM study area and base map are

given at Fig 1.3 & 1.4.

Plant & Green Belt Photographs are given at Fig. 1.5

Site lay out map is given at Fig 1.6


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Fig 1.3

Topo Sheet of the 10 KM study area


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Fig 1.4

Base map of the study area


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Fig 1.5

Plant & Green Belt Photographs


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Fig 1.6

Site Lay Out Plan


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5.0 Planning in Brief

The project is envisaged to be completed by December 2016, and the

production shall be initiated thereon. Consultants are identified for

preparing the detailed project report.

6. Resource requirements 6.1 Power Requirement and Supply/Source

The total power requirement is 6000 KVA. It shall be sourced from

TSCPDCL and D.G sets as alternative to Power failure.

6.2 Production facilities, Utilities and effluent handling facilities

Apart from the existing facilities it is proposed to add additional

production facilities, utilities and effluents treatment infrastructure with

an additional investment of Rs.40.0 Crores. The details are outlined in the

below table

TABLE 7.0 Production facilities/Utilities/ETP – Existing & Proposed

S.NO Details

Capacity/

No Current

Additions

After

expansion

Production facilities

1 Production Blocks No’s 9 5 13

2 Clean Rooms No’s 30 5 35

Utilities

3 Boilers (Coal Fired) TPH 6 15 21

4 DG sets KVA 1 X500, 1 X 380

1000 1880

5 Cooling Towers TR 670 1500 2170

6 Softener/DM plant M3/hour 4000 4000 8000

Effluent handling & treatment facilities

7 collection tanks-Storage

KL 4 4 8

8 Neutralisation tanks KL 1 1 2

9 Stripper, MEE, ATFD KLD 150 400 550

12 RO & Biological

treatment

KLD 150 400 550


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6.3 Land Requirement

The unit currently has 12.0 acres of land and out of which 5.0 acres of

green belt is developed. The land requirement for proposed expansion

activities will be 2.0 Acres which can be met from existing open area.

Below table provides the land statement. Detailed site lay out plan

outlining current and proposed expansion activities is given at Figure 1.6

Table 8.0 Land Statement

S.No Purpose Units Extent

1 Built up area Acres 2.0

2 Green belt Acres 5.0

3 Open area Acres 5.0

Total Acres 12.0

4 Area required for Proposed

expansion

Acres 2.0

7.0 Air Pollution

The Sources of air emissions from the plant are 6 TPH coal fired Boiler

and proposed 15.00 TPH coal fired boiler and additional DG sets

The process emissions from the second phase containing SO2, CH4, NH3 &

HCl are scrubbed with caustic and scrubbed waste send to MEE. Below

Table gives current proposed emission sources from the plant

Table 9.0

Emission Source – Current & Proposed

S.No

Parameter Capacity Fuel Anticipated emissions

Control system

Existing

1 Process --- -- HCl, SO2, NH3, Cl2

Scrubber

2 Boiler Stack 6 TPH Coal SPM, SO2,

NOx

Stack Ht 30

meters, bag filter & cyclone

dust collector

3 DG sets 1x 500 KVA Diesel SPM,SO2 Stack Height


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and 1 X 380

KVA

&NOx 4.5 & 3.9 Mts,

Acoustic enclosures

Proposed (additions)

1 Boiler 15 TPH Coal SPM,SO2

&NOx

Bag filter &

Stack Height 30 meters

2 DG set 1000 KVA Diesel SPM, SO2, NOx

Stack height of 6.3 meters &

acoustic

enclosure

8.0 Bulk Chemical Storages:

Following bulk chemical storage facilities are proposed for expansion

activity

Table No 10.0

Storage facilities of bulk chemicals

Sr

No

Capacity

(KL)

Name of the

solvent/Chemical MOC

Existing

1 15 Methanol MS Tank

2 30 Acetone MS Tank

3 15 Tolune MS Tank

4 15 IPA MS Tank

5 6.0 Chloroform Drums

Other Major chemicals

6 30 tons chlorine MS

cylinder

7 10 HCl HDPE

8 40 H2SO4 MS

Proposed

9 10.00 Toluene MS Tank


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9. Project Financial

The estimated cost of the expansion project is approximately 40.0 Crores.

Out of this Rs. 10.00 Crores will be for effluents treatment facilities and

rest for other process equipment and safety equipment

Project cost

Rs. In

Crores

Plant& machinery 15.00

Civil & Structural 5.00

Total 20.00

Pipe lines & insulation

20% on plant &

machinery 4.00

Electricals & instrumentation 10% on plant & machinery 2.00

Erection & commissioning & painting

8% on plant &

machinery and structures 1.60

Safety & Environment 10.00

Furniture, fixtures, computers, lighting etc 0.50

Total 38.10

Contingencies & pre-operative

expenses

1.90

Project cost say 40.00 Crores

1. introduction - welcome to...

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