annexures 3 gcplenvironmentclearance.nic.in/writereaddata/online/tor/05...calculated quantities of...
TRANSCRIPT
Annexures GCPL 1
List of Annexures Annexure – I Plant Layout
Annexure – II Manufacturing Process
Annexure – III Details of Storage of Solvents
Annexure – IV Water Balance & Details of Treatment and disposal of Effluent
Annexure – V Details of Treatment and Disposal of Solid Waste
Annexure – VI List of Raw materials & Quantity of Consumption
Annexure – VII Point Source Emissions – Stack Emission Characteristics
Annexure – VIII Details of Fugitive Emissions
Annexure – IX Risk Identification
Annexure – X Topo Map & Administrative Set-up Map
Annexures GCPL 2
ANNEXURE – I PLANT LAYOUT
Annexures GCPL 3
Annexures GCPL 4
Annexures GCPL 5
ANNEXURE – II MANUFACTURING PROCESS
Annexures GCPL 6
Manufacturing Process
Exis t in g
Calcium Gluconate
Gluconic Acid procured from market is neutralized with Calcium carbonate, filtered,
crystallised, centrifuged, dried, milled and packed.
Alternate process for the manufacture of Calcium Gluconate
Gluconic acid is neutralised with Calcium carbonate, filtered, crystallised, centrifuged,
dried, milled and packed.
Alternate process
NEUTRALISATION FILTERATION
CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
NEUTRALISATION FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
GLUCONO DELTA LACTONE + CaCO3 + WATER
(NEUTRALISATION) FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
Annexures GCPL 7
Sodium Gluconate
Gluconic acid brought from the market is neutralised with Sodium bi-carbonate, filtered,
concentrated, crystallised, centrifuged, dried, milled and packed.
Alternate process for the manufacture of Sodium Gluconate
Gluconic acid is neutralised with Sodium carbonate / Sodium Bicarbonate, filtered,
concentrated, crystallised, centrifuged, dried, milled and packed.
Alternate process
NEUTRALISATION FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
NEUTRALISATION FILTRATION
CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
GLUCONIC ACID +
SODIUM CARBONATE /
BICARONATE
(NEUTRALISATION)
FILTRATION SIEVING
PACKING
DRYING
Annexures GCPL 8
Potassium Gluconate
Gluconic acid brought from the market is neutralized with Potassium carbonate, filtered,
concentrated, crystallised, centrifuged, dried, milled and packed.
Alternate process for the manufacture of Potassium Gluconate
Gluconic acid is neutralised with Potassium carbonate / Potassium Bicarbonate, filtered,
concentrated, crystallised, centrifuged, dried, milled and packed.
Alternate process
NEUTRALISATION FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
NEUTRALISATION FILTRATION
CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
GLUCONIC ACID +
POTASSIUM CARBONATE
/ BICARONATE
(NEUTRALISATION)
FILTRATION SIEVING
PACKING
DRYING
Annexures GCPL 9
Magnesium Gluconate
Gluconic acid brought from the market is neutralised with Magnesium carbonate, filtered,
concentrated, crystallised, centrifuged, dried, milled and packed.
Alternate process for the manufacture of Magnesium Gluconate
Gluconic acid is neutralised with Magnesium carbonate, filtered, concentrated, crystallised,
centrifuged, dried, milled and packed.
Alternate process
NEUTRALISATION FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
NEUTRALISATION FILTRATION
CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
GLUCONIC ACID +
MAGNESIUM CARBONATE
(NEUTRALISATION) FILTRATION SIEVING
PACKING
DRYING
Annexures GCPL 10
Zinc Gluconate
Gluconic acid brought from the market is neutralised with Zinc carbonate/Zinc Oxide,
filtered, concentrated, crystallised, centrifuged, dried, milled and packed.
Alternate process for the manufacture of Zinc Gluconate
Gluconic acid is neutralised with Zinc carbonate/Zinc Oxide, filtered, concentrated,
crystallised, centrifuged, dried, milled and packed.
Alternate process
NEUTRALISATION FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
NEUTRALISATION FILTRATION
CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
GLUCONIC ACID + ZINC
CARBONATE / ZINC OXIDE
(NEUTRALISATION) FILTRATION SIEVING
PACKING
DRYING
Annexures GCPL 11
Manganese Gluconate
Gluconic acid brought from the market is neutralised with Manganese carbonate/
Manganese Oxide, filtered, concentrated, crystallised, centrifuged, dried, milled and packed.
Alternate process for the manufacture of Manganese Gluconate
Gluconic acid is neutralised with Manganese carbonate/ Manganese Oxide, filtered,
concentrated, crystallised, centrifuged, dried, milled and packed.
Alternate process
NEUTRALISATION FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
NEUTRALISATION FILTRATION
CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
GLUCONIC ACID +
MANGANESE CARBONATE /
MANGANESE OXIDE
(NEUTRALISATION)
FILTRATION SIEVING
PACKING
DRYING
Annexures GCPL 12
Calcium Lactate
Lactic Acid is neutralised with Calcium carbonate, filtered, crystallised, centrifuged, dried,
milled and packed.
Calcium Glubionate
In this process, calculated quantities of both Calcium Gluconate and Calcium Lactobionate
are charged in the blender and mixed, sieved and packed.
Alternate Process for the manufacture of Calcium Glubionate
Calculated quantities of Calcium Gluconate and Calcium Lactobionate are mixed in DM
water, filtered, dried, sieved and packed.
NEUTRALISATION FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
BLENDING SIEVING PACKING
MIXING SIEVING PACKING FILTERING DRYING
Annexures GCPL 13
Calcium Lacto Gluconate
In this process, calculated quantities of Calcium Lactate and Calcium Gluconate are charged
in the blender and mixed, sieved and packed.
2. Alternate Process for the m anu facture of Ca lciu m La ct o Glucon a t e
Calculated quantities of Calcium Lactate and Calcium Gluconate are mixed in DM water,
filtered, dried, sieved and packed.
3. Alternate Process for the m anu facture of Ca lciu m La ct o Glucon a t e
Calculated quantities of Gluconic Acid, Lactic Acid are reacted with calcium carbonate,
filtered, dried, sieved and packed.
4. Alternate Process for the m anu facture of Ca lciu m La ct o Glucon a t e
MIXING SIEVING PACKING FILTERING DRYING
BLENDING SIEVING PACKING
GLUCONIC ACID + LACTIC
ACID + CaCO3
(NEUTRALISATION) FILTRATION SIEVING
PACKING
DRYING
GLUCONO DELTA LACTONE
+ LACTIC ACID + CaCO3
(NEUTRALISATION) FILTRATION SIEVING
PACKING
DRYING
Annexures GCPL 14
Calcium Lactobionate
Calculated quantities of Lactose, Sodium bromide, Calcium Carbonate are mixed in water,
electrolysed, filtered, vaccum concentrated, crystallised with alcohol, centrifuged, milled,
dried and packed in bags/ Fibre drums.
ELECTROLYSIS FILTRATION
CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
VACCUM
CONCENTRATION
LACTOSE,
SODIUM BROMIDE,
CALCIUM CARBONATE,
DM WATER
Annexures GCPL 15
Calcium Borogluconate :
1. Calculated quantities of calcium gluconate and Boric acid are charged in the blender
and mixed sieved & packed.
2. Alternate Process
Calculated quantities of calcium gluconate & Boric acid dissolved in DM Water, filtered,
spray dried, sieved & packed.
Ferrous Gluconate :
BLENDING SIEVING PACKING
CALCIUM
GLUCONATE +
BORIC ACID +
DISSOLVED IN DM
WATER
FILTERED DRIED
PACKED SIEVED
CALCIUM
GLUCONATE +
FERROUS
SULPHATE + DM
WATER
FILTERATIO
N
CONCENTRATIO
N
PACKING MILLING
DRYING
Annexures GCPL 16
Man u factu rin g P rocess
P roposed
1 IRON SUCROSE
Ferr ic Chlor ide is dissolved in wa ter and sodium bica rbona te solu t ion is added
to precipita te fer r ic hydroxide which is filt ered.
Above fer r ic hydroxide is mixed with sucrose and hea ted to get iron sucrose in
solu t ion . Which is concent ra ted to get th ick mass which is added with vigorous
st ir r ing to DNS and then methanol to precipita te iron sucrose solid. This is
cent r ifuged and slur r ied with DNS and acetone aga in to remove the impur it ies.
The wet materia l is dr ied under vacuum, pulver ized, redr ied, milled, blended as
needed and packed.
Raw material:
Ferric Chloride
Sodium carbonate
Sucrose
DNS denatured spirit
Methanol
Acetone
Raw m ateria l con su m ption per kg of ou tpu t
Ferric Chloride = 0.2 kg / kg
Sodium Carbonate = 0.04 kg / kg
Sucrose = 2 kg / kg
DNS = 8 L / kg
Methanol = 5 L / kg
Acetone = 1 L / kg
Annexures GCPL 17
P ROCESS FLOW CHART
Sodium carbona te
solu t ion
MLR collect ion
Hea t
DNS
MLR collect ion
methanol
DNS
Acetone MLR collect ion
Water + Ferric Ch loride
Filtration of Ferric
h ydroxide
Ferric h ydroxide Cake +
Su gar
Con cen trated
Filtration
Filte r Mass
Filtration
Vacu u m Dryin g
Millin g , Blen din g & P ackin g
Annexures GCPL 18
2. CALCIUM DOBESYLATE
Stage-I: Sulphur ic acid is a dded to a suspent ion of hydroquinone in ethylene di
ch lor ide. After the su lfona t ion , water is added and aqueous layer separa ted.
Stage-II: aqueous layer is neut ra lized with a slur ry of ca lcium carbona te in
wa ter , cent r ifuged to separa te ca lcium sulfa te.
Liquid from cent r ifuge is concent ra ted, ch illed, the product filt ered and washed
with isopropanol and dr ied.
Raw m ateria l:
Hydroquinone
Sulphuric acid
Calcium carbonate
Ethylene di chloride
Isopropanol
Raw m ateria l con su m ption per kg of ou tpu t
Hydroquinone = 1.2 kg
Sulphuric acid = 1.6 kg
Calcium carbonate = 1.6kg/kg
Ethylene di chloride = 4L/kg
Isopropanol = 2L/kg
Annexures GCPL 19
P ROCESS FLOW CHART
Stage -1
su lphur ic acid
layer separation
Stage -II
ca lcium carbona te
cen trifu ge
concen trated
ch illed
isopropanol
Hydroqu in on e + e th ylen e d i
ch loride
Aqu eou s layer
Liqu id from cen trifu ge
Crystallisation
Dryin g
Cen trifu gation
Millin g , Blen din g & P ackin g
Residu e
Annexures GCPL 20
3. TIEMMONIUM METHYL SULPFATE (TMS)
Morpholine is reacted with 2-acetyl th iophene and p-formaldehyde in the
presence of hydrochlor ic acid in dena tured spir it (DNS) to get the cor responding
mannich base as HCl sa lt . The above HCl sa lt is basified in toluene to get the
corresponding mannich ketone base. This is reacted with phenyl magnesium
bromide in tet rahydrofuran to get t iemmonium hydrochlor ide which is pur ified
using methanol slur ry. The pure hydrochlor ide is conver ted to base and t rea ted
with dimethyl su lfa te in acetone to get the t iemmonium methyl su lfa te. This is
dr ied in a vacuum oven, milled, blended and packed.
Raw m ateria l:
Morpholine
2- Acetyl thiophene
P-Formaldehyde
Hydrochloric acid
Denatured spirit (DNS)
Phenyl magnesium bromide
Dimethyl Sulfate
Tetrahydrofuran
Methanol
Toluene
acetone
Raw m ateria l con su m ption per kg of ou tpu t
Morpholine = 1 kg / kg
2- Acetyl th iophene = 1.5 kg / kg
P-Formaldehyde =0.7 kg / kg
Hydrochlor ic acid = 5.7 kg / kg
Dena tured spir it (DNS) = 6L / kg
Phenyl magnesium bromide =2.3 kg / kg
Dimethyl Sulfa te =0.5 kg / kg
Annexures GCPL 21
Methanol = 3L/kg
Tetrahydrofuran = 2L/kg
Toluene = 8 L/kg
Acetone = 5L/kg
P ROCESS FLOW CHART
Con. HCl
Reflux
MLR collect ion
Phenyl magnesium bromide
Con. HCl
Methanol MLR collect ion
Dimethy su lpha te
MLR collect ion
Morph olin e + 2- Ace tyl
th ioph en e + P -Form aldeh yde
+DNS
Cool, Cen trifu gation ,
Bas ification
Keton e Base
Qu en ch in g ice w ater
Cen trifu gation
Basification w ith Am m on ia
Cen trifu gation
Vacu u m Dryin g
Annexures GCPL 22
4 ETHAMSYLATE
Stage-I: Sulphur ic acid is added to a suspent ion of hydroquinone in ethylene di
ch lor ide. After the su lfona t ion , water is added and aqueous layer separa ted.
Stage-II: aqueous layer is neut ra lized with diethylamine, concent ra ted, ch illed,
the product filt ered and washed with isopropanol and dr ied.
Raw m ateria l:
Hydroquinone
Sulphuric acid
Diethylamine
Ethylene di chloride
Isopropanol
Raw m ateria l con su m ption per kg of ou tpu t
Hydroquinone =0.8 kg/kg
Sulphuric acid = 1.5 kg/kg
Diethylamine = 1.6 L/kg
Ethylene di chloride = 2.3L/kg
Isopropanol = 0.5L/kg
Millin g , Blen din g & P ackin g
Annexures GCPL 23
P ROCESS FLOW CHART
Stage -I:
Suphur ic acid
wa ter
layer separation
s tage -II
diethylamine
con cen tration
isopropanol
h ydroqu in on e + e th ylen e d i
ch loride
Su lph on ated m ass
Aqu eou s layer
Crystallisation
Dryin g
Cen trifu gation
Ch ill, re s idu e
Annexures GCPL 24
5 TOLPERISONE HCl
Mixture of 4-methyl propiophenone, piper idin e, and hydrochlor ic acid hea ted to
reflux in 1,3-dioxalone. After the react ion is over , dilu ted with ethyl aceta te and
chilled with st ir r ing. Product formed is cen t r ifuged, washed with ethyl aceta te.
The crude product is pur ified with methanol and ethyl a ceta te using charcoa l.
Raw m ateria l:
1.4-methyl propiophenone
2. piper idine
3.1,3-dioxalone
4. conc. hydrochlor ic acid
5. ethyl aceta te
6. methanol
Raw m ateria l con su m ption per kg of ou tpu t
1.4-methyl propiophenone 1.0 kg
2. piper idine 0.6 kg
3.1,3-dioxalone 1.5 kg
4. conc.hydrochlor ic acid 0.025 L
5. ethyl aceta te 3 L
6. methanol 1.0 L
Millin g , Blen din g & P ackin g
Annexures GCPL 25
P ROCESS FLOW CHART
Reflux
ch ill
stage-1
charcoa l
filt er
4-m eth yl
propioph en on e+piperid in e+
HCl + 1,3-d ioxolan e
Dilu te w ith e th yl ac tate
Cen trifu gation
Dissolve s tage -1 in m eth an ol
cen trifu gation
Filtrate , con cen trate , add
e th yl ace tate , ch ill
Vacu u m dryin g
Annexures GCPL 26
6. a . CALCIUM GLYCEROP HOSP HATE
Stage – I: Epichlorohydr in is hydrolised with dilu te acid, and reacted with
Tr i sodium phospha te, to get Crude sodium Glycerophospha te.
Stage –II : To the Above crude Sodium Glycerophospha te solu t ion , Ca lcium
chlor ide is added to get Crude Ca lcium Glycerophospha te
Stage – III : crude Ca lcium Glycerophospha te is washed with DNS: Water
mixture to get Pure Ca lcium Glycerophospha te, which is cent r ifuged and dr ied.
Raw m ateria l:
1. Epichlorohydrin
2. Trisodium phosphate
3. Calcium chloride
4. Denatured spirit (DNS)
Raw m ateria l con su m ption per kg of ou tpu t
1. Epichlorohydrin =1.5 kg / kg
2. Trisodium phosphate = 6 kg / kg
3. Calcium chloride = 2 kg / kg
4. Denatured spirit (DNS) = 5L / kg
Millin g , Blen din g & P ackin g
Annexures GCPL 27
P ROCESS FLOW CHART
Stage - I
Reflux
Hot condit ion
Stage -II
Calcium chlor ide
Stage -III
DNS: Water
Epichlorohydrin + water
Reaction w ith Trisodiu m
ph osph ate
Ch arcoal treatm ent &
Filtration
Reaction w ith calc iu m
ch loride
Dryin g
Cen trifu gation & Slu rry
w ash
Millin g , Blen din g & P ackin g
Annexures GCPL 28
6.b. MAGNESIUM GLYCEROP HOSP HATE
Stage – I: Epichlorohydr in is hydrolised with dilu te acid, and rea cted with
Tr i sodium phospha te, to get Crude sodium Glycerophospha te.
Stage –II : To the Above crude Sodium Glycerophospha te solu t ion ,Magnesium
ch lor ide is added to get Crude Magnesium Glycerophospha te
Stage – III : crude Magnesium Glycerophospha te is washed with DNS: Water
mixture to get Pure Magnesium Glycerophospha te, which is cent r ifuged and
dr ied
.
Raw m ateria l:
4. Epichlorohydrin
5. Trisodium phosphate
6. Magnesium chloride
7. Denatured spirit (DNS)
Raw m ateria l con su m ption per kg of ou tpu t
8. Epichlorohydrin =1.5 kg / kg
9. Trisodium phosphate = 6 kg / kg
10. Magnesium chloride = 3 kg / kg
11. Denatured spirit (DNS) = 5L / kg
Annexures GCPL 29
P ROCESS FLOW CHART
Stage - I
Reflux
Hot condit ion
Stage -II
Magnesium chlor ide
Stage -IV
DNS: Water
Epichlorohydrin + water
Reaction w ith Trisodiu m
ph osph ate
Ch arcoal treatm e nt &
Filtration
Reaction w ith Magn es iu m
ch loride
Dryin g
Cen trifu gation & Slu rry
w ash
Con cen tration
Annexures GCPL 30
6. c . SODIUM GLYCEROP HOSP HATE
Stage – I: Epichlorohydr in is hydrolised with dilu te acid, and reacted with
Tr i sodium phospha te, to get Crude sodium Glycerophospha te solu t ion which is
concent ra ted and filt ered to get Crude sodium Glycerophospha te
Stage – II : crude Sodium Glycerophospha te is washed with DNS: Water
mixture to get Pure Sodium Glycerophospha te, which is en t r ifuged and dr ied
.
Raw m ateria l:
1. Epichlorohydrin
2. Trisodium phosphate
3. Denatured spirit (DNS)
Raw m ateria l con su m ption per kg of ou tpu t
4. Epichlorohydrin =1 kg / kg
5. Trisodium phosphate = 6 kg / kg
6. Denatured spirit (DNS) =5L / kg
Millin g , Blen din g & P ackin g
Annexures GCPL 31
P ROCESS FLOW CHART
Stage - I
Reflux
Hot condit ion
DNS
Stage -II
DNS: Water
Epichlorohydrin + water
Reaction w ith Trisodiu m
ph osph ate
Ch arcoal treatm ent &
Filtration
Crysta llisation
Dryin g
Cen trifu gation & Slu rry
w ash
Con cen tration
Annexures GCPL 32
7 FENSPIRIDE HYDROCHLORIDE
MANUFACTURING FLOWCHART:
Stage -1:
1-(2-ph en yle th yl)-4-p iperidon e
Hydroch loric ac id
Water, ce n trifu ge , dry
S tage -II : Fen spiride Hydroch loride Cru de
Zin c Du st
bas ify w ith Aq. am m on ia
Dich lorom eth an e
Con cen tration
Toluen e , Die th y l carbonate
w ater, to lu en e
ac id ify ,
Hydroch loric ac id
cool, cen trifu ge , dry
Millin g , Blen din g & P ackin g
Nitrom eth an e+ DMSO +
P otass iu m Carbon ate , 0 deg .C
Stage -1
Meth an ol + Stage -1+
Hydroch loric ac id , <5 deg .C
Dich lorom eth an e layer
to lu en e layer
Stage -II
Res idu e
Annexures GCPL 33
S tage -III: P u rification
S tage -II
Heat
Ace ton e
Cool & Cen trifu ge ,
Man u factu rin g process for th e Fen spiride Hydroch loride :
Stage -I: 4-(n it romethyl)-1-phenethylpiper idin -4-ol is prepared by react ing 1-(2-
phenylethyl)-4-piper idone with n it romethane and potassium carbona te in
dimethylsu lfoxide. stage-1 is isola ted by quenching in wa ter Cent r ifuging.
Stage -II: Fenspir ide hydrochlor ide crude is prepared by the reduct ion of
stage-I with zinc dust and hydrochlor ic acid, basifica t ion with aqueous
ammonia and ext ract ing with dich loromethane. Dichloromethane ext ract is
concent ra ted to get 4-(aminoethyl)-1-phenylpiper idin -4-ol, which is reacted
with diethylca rbona te in the presence of sodium methoxide to get Fenspir ide
base. This is t rea ted with Hydrochlor ic acid to get Fenspir ide hydrochlor ide
crude.
Stage -III: Fenspir ide HCl crude dissolved in methanol , t rea ted with Act ivated
ca rbon . filt ered, filt ra te concent ra ted completely, Acetone is added , solid
cent r ifuged, dr ied under vacuo <60 deg.C , milled ,sieved and packed.
Meth an ol
Con cen trate
Dryin g, m illin g , S ievin g+
packin g
Annexures GCPL 34
8 CLOZAPINE :
MANUFACTURING FLOW CHART
2-ch loro ben zoic ac id
reduct ion
wa ter +sodium dith iona te
s tage -1
cyclisa t ion , xylene
s tage -2
N-m eth ylp iperazin e , TiCl4
s tage -3
recrysta llisation
Brie f process description : Stage -1:
4-chloro-2-n it ro an iline is reacted with 2-chloro bezoic acid and th e resu lt ing
product is reduced in -situ with sodium dithiona te in wa ter to get 2-( 4-ch loro
-2-am in o d iph en ylam in o)ben zoic ac id s tage -1
S tage -2:
Stage-1 is cylised in refluxing xylene to get 8-ch loro-5H-ben zo-
[b,e ][1,4]d iazepin e -11-10H-on e
Stage -3:
4-ch loro-2-n itro an ilin e
+potass iu m carbonate
+DMF
2-( 4-ch loro -2-am in o
d iph en ylam in o)benzoic ac id
8-ch loro-5H-ben zo-
[b,e ][1,4]d iazepin e -11-10H-on e
cru de c lozapin e
pu re c lozapin e
Dryin g, s iev in g an d
packin g
Annexures GCPL 35
Stage-2 is reacted with N-methyl piperazine in presence of t it an ium
tet rachlor ide to get crude clozapine (stage-3)
Stage -4: pu re c lozapin e
Crude clozapine is pur ified to pure clozapine by dissolving in methanol ,
charcolising, filt er ing, concent ra t ing and cooling. The product is cent r ifuged,
dr ied under vacuum below 60 deg.C , milled , sieved and packed.
9 NIFUROXAZIDE MANUFACTURING FLOW CHART:
Syn th es is of Nifu roxazide :
Nitrofu rfu ral d iace tate
Heat
4-hydroxy benzohydrazide
Hydroch loric ac id
Heat & Cool
Cen trifu ge
Meth an ol
Cen trifu ge
Man u factu rin g procedu re for Nifu roxazide :
Nit rofufura l Diaceta te reacts with 4-hydroxy benzohydrazide in the presence of
su lfur ic acid in DNS to form the Nifuroxazide.
Water +Su lph uric ac id+
DNS
Reaction m ass
Reaction m ass
Wet cake , re flu x
Dryin g, m illin g , s iev in g,
packin g
Annexures GCPL 36
10 OXETACAINE MANUFACTURING FLOW CHART:
Stage -I:
Su lfu ric ac id
wa ter
Cen trifu ge , dry
S tage -II: Methyla t ion
Dim eth yl su lfate
P otass iu m h ydroxide
Heatin g
Water
Extraction & Disti llation
Stage -III:
P EG-400
h eatin g Sodiu m Hydroxide
d ich loro e th an e
Water
Extraction
Layer separation
Ch loroace ty l ch loride
Sodiu m h ydroxide
Extraction & Disti llation
Dimethyl benzyl carbinol +
Acetonitrile
S tage -I+ Tolu en e
Dim et
s tage -1
Reaction Mass
Res idu e
Stage -II
Reaction Mass
Organ ic layer
Res idu e
Annexures GCPL 37
S tage -IV: Oxetaca ine crude
Etan ol am in e Tolu en e
Sodiu m Hydroxide
Heatin g
Water
Extraction , layer separation
Hydroch loric ac id
Extraction , layer separation
Am m on ia
Cen trifu ge , dry
S tage -V: Purifica t ion
Isopropyl a lcoh ol
Water
Cen trifu ge
Man u factu rin g P rocess of Oxe tacain e :
S tage -1: Dimethyl benzyl ca rbinol is reacted acetonit r ile and su lfur ic acid to
get stage-I.
Stage -I1: Stage-I methyla ted with dimethyl su lfa te in the presence of
potassium hydroxide in toluene to stage-II.
Stage -II1: Stage-II hydrolyzed with sodium hydroxide and reacted with
ch loroacetyl ch lor ide to stage-III.
Stage -IV: Stage-III react ed with ethanol amine in the presence of sodium
hydroxide in toluene to stage-IV (Oxetaca ine crude).
Stage -V: Oxetacine crude crude pu r ified using Isopropyl a lcohol and water to
get pure Oxetaca ine
Residu e
Reaction
Organ ic layer
Acid ic layer
s tage -IV
Stage -IV
Dryin g, m illin g , s iev in g,
packin g
Annexures GCPL 38
11 BENFOTIAMINE
Mixture of th iamine HCl and or thophosphor ic acid is hea ted and phosphorous
pentoxide is added slowly over a per iod. Dilu ted by a dding wa ter and
Hydrolysed by hea t ing to reflux
The above solu t ion is basified with sodium hydroxide and t rea ted with benzoyl
ch lor ide in methylene di ch lor ide a t low tempera ture. After the react ion ,
cent r ifuged to remove inorganics, the MLR is concent ra ted and filt ered. The
filt ra te is acidified to get the crude benfot iamine which is cent r ifuged and
washed with water .
crude product is dissolved in dilu te sodium hydroxide, charcolised, filt ered,
acidified to get the pure product which is cent r ifuged, washed with wa ter ,
methanol and spin dr ied. The wet mater ia l is dr ied under vacuum, pulver ized,
milled, blended as needed and packed.
Raw m ateria l:
1. th iamine HCl
2.or thophosphor ic acid
3.phosphorous pentoxide
4.Sodium hydroxide
5.benzoyl ch lor ide
6.Hydrochlor ic acid
7.methylene ch lor ide
8.methanol
Raw m ateria l con su m ption per kg of ou tpu t
1. th iamine HCl 2.5 kg
2.or thophosphor ic acid 3.5 kg
3.phosphorous pentoxide 2.5 kg
4.Sodium hydroxide 2.5 kg
5.benzoyl ch lor ide 1.5 kg
6.Hydroch lor ic acid 2.5 L
7.methylene ch lor ide 5.0 L
Annexures GCPL 39
8.methanol 2.0 L
P ROCESS FLOW CHART
Phosphorous pentoxide
hea t
wa ter
reflux, cool
benzoyl ch lor ide
in DCM
hydrochlor ic acid
Hydrochlor ic acid
Th iam in e HCl +
orth oph osph oric acid
Reaction m ixtu re
Reaction m ixtu re+ sodiu m
h ydroxide
Cen trifu gation
Cen trifu gation
Millin g , Blen din g & P ackin g
Above so lid + aq. sodiu m
h ydroxide
Ch arcoalise , fi lte r
Cen trifu ge , MLR con cen trate
Vacu u m dryin g
Annexures GCPL 40
12 CALCIUM FOLINATE
Folic acid dissolved in wa ter and t rea ted with sodium borohydr ide under
cooling. The mixture is quenched in to hydrochlor ic acid and then formyla ted
using formic acid. The react ion solu t ion is concent ra ted under vacuum and
cent r ifuged to get stage-1(formyl folic acid). Stage-1 is reacted with
t r iethylamine in wa ter and then conver ted to the cor responding ca lcium sa lt
using ca lcium chlor ide. The product is precipita ted by adding DNS. The crude
product is pu r ified using water and DNS. Washed with acetone and dr ied. The
wet product is dr ied under vacuum, milled and sieved and packed.
Raw m ateria l:
1. folic acid
2. sodium borohydr ide
3. conc. HCl
4. t r iethyl amine
5. ca lcium chlor ide
6. DNS
7.acetone
8.formic acid
9. Methanol
Raw m ateria l con su m ption per kg of ou tpu t
1. folic acid 2.5 kg
2. sodium borohydr ide 5 kg
3. conc. HCl 7 L
4. t r iethyl amine 2 L
5. ca lcium chlor ide 2 kg
6. DNS 75 L
7.acetone 5 L
8.formic acid 70 L
Annexures GCPL 41
9. methanol 5L
P ROCESS FLOW CHART
Sodium boro hydr ide
Formic acid
Stage -1
t r iethylamine
DNS
ca lcium chlor ide
Qu en ch in to HCl
Filtration , con cen tration
Ce n trifu gation
Stage -1 in w ater
Dryin g u nder vacuu m
Millin g , s iev in g Blen din g &
P ackin g
Reaction m ixtu re
cen trifu gation
recrysta llisation
cen trifu gation
Folic ac id in w ater
Annexures GCPL 42
13. TRIMETAZIDINE HYDROCHLORIDE
Stage -I: Synthesis of Tr imetazidine Hydrochlor ide crude
P iperazin e
5% P alladiu m on Carbon
Hydrogen ator
Centrifu ge , Con cen trate
Tolu en e ,w ater
Extraction , layer separation
isopropan olic HCl,cool
Centrifu ge , dry
S tage -II: Purifica t ion of Tr imetazidine crude
Meth an ol
ac tivated carbon
h eat, fi lte r
concen trate
Ace ton e
Cen trifu ge
Man u factu rin g procedu re for Trim etazid in e Hydroch loride :
Stage -I: 2,3,4-t r imethoxy benza ldehyde and piperazine is condensed and
reduced using Pa lladium on ca rbon and Hydrogen gas and isola ted as ,
t r imetazedine hydrochlor ide crude
2,3,4-trim eth oxy
ben zaldeh yde
+ Meth an ol
Reaction m ass
Res idu e
Tolu en e Layer
S tage -I
Stage -I
fi ltrate
Res idu e
Dryin g, Millin g , S ievin g,
packin g
Annexures GCPL 43
Stage -II: Stage-I pur ified by dissolving in methanol, charcolisa t ion , filt ra t ion ,
concent ra t ion . pure Tr imetazidine hydrochlor ide. is isola ted by adding acetone.
14 CALCIUM METHYLFOLATE
MANUFACTURING FLOWCHART:
Stage -I: Synthesis of Ca lcium Methylfola te crude
Sodiu m Hydroxide
sodiu m boroh ydride
ac id ification , cen trifu gation
Sodiu m Boroh ydride
Form aldeh yde
ac id ification , cen trifu gation
Calc iu m ch loride
Cen trifu gin g ,dryin g
S tage -II: P u rification of Calc iu m m ethylfo late :
Water
h ydroch loric ac id ,
Cen trifu ge
Sodium h ydroxide
Calc iu m ch loride
ca lc iu m ch loride
Cen trifu ge
Stage -I
so lid +w ater
P rocess w ater+ Folic ac id
Cen trifu gate
Dryin g, m illin g , s iev in g,
packin g
Cen trifu gate
crude CaMeF
Annexures GCPL 44
Man u factu rin g process for Calc iu m meth ylfo late :
Stage -I: A solu t ion of Folic acid in sodium hydroxide is reduced with Sodium
borohydr ide to get tet rahydrofola te, which is reacted with formaldehyde and
reduced aga in with sodium borohydr ide and then t rea ted with ca lcium
chlor ide to get Calcium methylfola te crude.
Stage -II: m eth yl fo lic ac id is prec ip itated by ac id ification of th e cru de
produ ct w h ich is redisso lved in Sodium hydroxide, charcoa lised, filt ered
and reprecipita ted as pure ca lcium methyl fola te by adding filt ered ca lcium
chlor ide solu t ion .
15 UBIQUINOL ACETATE
MANUFACTURING FLOWCHART: Pyridine , Zinc Dust Acetic Anhydride Cooling, acidification, n-heptane, layer separation concentration DNS Centrifuge Manufacturing Procedure of Ubiquinol acetate: Coenyme Q10 reduced with Zinc dust in the presence of Hydrochloric acid, reacted with acetic anhydride to get Ubiquinol acetate, which is extracted with n-heptane and isolated by addition of DNS.
Coen zym e Q10
n- heptane layer
residue
Drying, Milling, sieving, Packing
Annexures GCPL 45
16. STRONTIUM RANELATE
Stage-I: ethyl acetone dica rboxila te is made by react ing cit r ic acid with
ch lorosulfonic acid in methylene ch lor ide
Stage – II: ethyl acetone dica rboxila te is condensed with , Malano n it r ile and
Sulphur in presence of t r iethylamine to get stage-II
Stage –III: Stage –II is reacted with Methyl bromoaceta te and Potassium
carbona te in Acetone, and to get a lkyla ted Stage –II.
Stage –IV; Stage –III reacted with st ront ium hydroxide in wa ter under reflux
condit ion to get the fina l product which is washed with wa ter , dr ied, milled and
packed.
Raw m ateria l:
Triethylamine/Morpholine,
Methanol,
Malano nitrile
Sulphur
Acetone,
Potassium carbonate and
Methyl bromoacetate
Strontium hydroxide
isopropanol
Raw m ateria l con su m ption per kg of ou tpu t
Citric acid = 2 kg / kg
Chlorosulphonic acid = 2kg / kg
Methylene dichloride =2 L / kg
Morpholine = 1.8 kg / kg
Methanol = 8 L / kg
Malano nitrile = 0.6 kg / kg
Isopropanol = 2L/kg
Suphur = 0.2 kg / kg
Acetone = 8 L / kg
Potassium carbonate = 1.2kg / kg
Methyl bromoacetate = 1.3 kg / kg
Strontium hydroxide = 1.5 kg / kg
Annexures GCPL 46
P ROCESS FLOW CHART
Stage - I
Cit r ic acid
Water
Stage - II
Hot condit ion
Water
Stage -III
Hot condit ion
Methylene dichloride +
Chlorosulphonic acid
Qu en ch in g
Morph olin e + m ethan ol +
Malan o n itrile + Suph u r
Qu en ch in g
Ace ton e + P otass ium
carbon ate + Meth yl
brom oace tate
Filtration
Filtration & Con cen tration
Annexures GCPL 47
Stage -IV
Water
Hot condit ion
17. P HENYRAMIDOL HYDROCHLORIDE
Stage -1: Synthesis of Phenyramidol Hydrochlor ide crude
Styre n e Oxide
Water + Eth yl ace tate
Extraction , layer separation
IP A.HCl
Cen trifu ge
2-Am in opyrid in e +DMF + Lith iu m
am ide
Reaction mass
Organ ic layer
P h en yram idol Hydro ch loride cru de
s tage -1
Reaction w ith s tron tiu m
h ydroxide
Dryin g
Filtration
Millin g , Blen din g & P ackin g
Annexures GCPL 48
S tage -2 :Pure Phenyramidol Hydrochlor ide
Heatin g , fi ltration
Distillation
Aceton e
Man u factu rin g process for P h en yram idol h ydroch loride :
Stage -I: 2-Amino pyr idine reacts with styrene oxide in the presence of lith ium
amide to form the Phenyramidol hydrochlor ide crude.
Stage-II: Phenyramidol hydrochlor ide pur ified by using recrysta llisa t ion using
methanol and acetone to get pure Phenyramidol hydrochlor ide.
Meth an ol + Stage -1+activated
carbon
fi ltrate
Cen trifu gation , dryin g,
m illin g s iev in g & packin g
Res idu e
Annexures GCPL 49
18 IRON SORBITOL COMPLEX
MANUFACTURING FLOWCHART:
citric acid
basification with Sodium Hydroxide
Ferric Chloride
filter, adjust pH with Citric acid
DNS DNS
Procedure: a solution Sorbitol , dextrin and citric acid in water is heated and complexed
with Ferric chloride solution in the presence of sodium hydroxide. pH is adjusted with
citric acid , filtered . the complex is isolated by adding DNS. which is centrifuged and dried
Sorbitol + Water+dextrin
Reaction Mass
Filtrate
Centrifuge
Drying, Milling, Sieving, Packing
Annexures GCPL 50
19 NAFTIFINE HYDROCHLORIDE:
Stage -I: Naft ifine hydrochlor ide crude
Cin n am yl Ch loride
Heat, cen trifu ge
Hydroch loric ac id
Cen trifu ge , dry
Stage -II: Purifica t ion of Naft ifine hydroch lor ide
Cen trifu ge , con cen trate
Isopropyl a lcoh ol
cool, Cen trifu ge
Man u factu rin g P rocedu re for Naftifine Hydroch loride .
Stage -I: N-Methyl –naphthyl- methanamine reacted with Cinnamyl ch lor ide in
the presence of sodium bica rbonate in toluene to get Naft ifine hydrochlor ide
crude.
S tage -II: Stage-I pur ified by dissolving in methanol, charcolisa t ion , filt ra t ion
concent ra t ion and isopropyl a lcohol added to get Naft ifine hydrochlor ide.
N-Meth yl –n aph th yl
m eth an am in e
+Sodiu m Bicarbonate+ Tolu en e
Stage -II + Meth an ol+activated
carbon
s tage -1
re s idu e
Dryin g, Millin g ,
s iev in g
cen trifu gate
Annexures GCPL 51
20 ESMOLOL HYDROCHLORIDE MANUFACTURING FLOWCHART:
Stage-I
Malonic acid Heat Water Stage-II: hydrogen gas sulphuric acid concentration Stage-III: Sodium Hydride Epichlorohydrin Water , Ethyl acetate layer separation, concentration Stage-IV
Isopropylamine Concentration
Ethyl acetate, HCl filtration
Stage-V:
Ethyl acetate Acetone
Crystallization
4-Hydroxy benzaldehyde +
Pyridine
Reaction Mass
Centrifuge and Drying
Stage-I +
5% Pd/C + methanol
stage-II
Stage-II +
Dimethylformamide
Reaction
stage-III
Stage-III+ Methanol
Stage-IV
Esmolol Hydrochloride Centrifuge, Drying, Packing
Esmolol Base
Esmolol Hydrochloride
Crude
Annexures GCPL 52
Manufacturing procedure of Esmolol Hydrochloride:
Stage-I : 4-hydroxy benzaldehyde condensed with malonic acid in the presence of
pyridine to give the 3-(4-hydroxyphenyl)acrylic acid (Stage-I).
Stage-II : Stage-I reduced with Hydrogen and Pd/C to get 3-(4-
hydroxyphenyl)propanoic acid . Which is esterified with methanol to get
methyl-3-(4-hydroxyphenyl)propanoate (Stage-II).
Stage-III : Stage-II condensed with Epichlorohydrin in the presence of sodium
hydride to get methyl-3-[4-(3-chloro-2-hydroxypropoxy)phenyl]
propanoate (Stage-III).
Stage-IV : Stage-III condensed with isopropyl amine to get Esmolol base, which is
treated with hydrochloric acid to get Esmolol hydrochloride
Stage-V : Stage-IV is re crystallised from ethyl acetate and acetone to get pure
Esmolol Hydrochloride.
21 CALCIUM L-5- METHYLTETRAHYDROFOLATE MANUFACTURING
FLOW CHART:
Stage -I: Synthesis of Ca lcium Methylfola te
Sodiu m Hydroxide
Dissolu tion
con c . HCl Sodiu m boro h ydride
Cen trifu ge
Form aldeh yde
Sodiu m Boroh ydride
acidify Conc.HCl
Cen trifu ge
Calc iu m ch loride
Centrifu ge
P rocess w ater+ Folic ac id
Filtrate
Reaction m ass
F iltrate
s tage -1
Annexures GCPL 53
Stage -II: Synthesis of Methylfola te sa lt with S-phenylethylamine
Hydroch loric ac id
Cen trifu ge
Water
S-ph en yl e th yl am in e
Centrifu ge
DNS
Cen trifu ge , dry
S tage -III: Synthesis of Ca lcium -L-Methylfola te Crude:
L-Cyste in e
Cen trifu ge
DNS, Ace ton e
Centrifu ge ,dry
Step-IV: Pur ifica t ion of Ca lcium -L-methylfola te:
Water
Heatin g & Coolin g
Man u factu rin g proces s for th e preparation of Calc iu m L-Meth ylfo late :
Stage -I: a solu t ion of Folic acid in sodium hydroxide is reduced using Sodium
borohydr ide to t et rahydrofola te ,which is reaced with formaldehyde to get
Stage -1
Wet Cake
P roduct (w e t
cake )
s tage -II
S tage -II + Water + DNS
Reaction m ass
Wet Cake
s tage -III
S tage -III
Reaction
Dryin g, m illin g , S ievin g, P ackin g
Annexures GCPL 54
5,10- methyene tet rahydrofola te th is is hydrolysed and reduced by sodium
borohydr ide to get Ca lcium DL- methylfola te.
Stage -II: Calcium DL- methylfola te reacted with S-phenyl methylamine to get
the S sa lt .
Stage -III: a solu t ion of The above amine sa lt is t rea ted with ca lcium chlor ide
to get L-methyl fola te crude Stage -IV: Calcium L-Methylfola te crude is
pur ified in wa ter to get pure Ca lcium L-methyl fola te.
22 MINOXIDIL:
P ROCESSES FLOW CHART
Stage -I: Prepara t ion of Urea Hydrogen peroxide adduct
Urea
cool, cen trifu ge
Stage -II : Prepara t ion of n -Oxide
a ) P reparation of cata lyst so lu tion
S tage -I addition
b) P reparation of n -Oxide
Ca ta lyst solu t ion
Cen trifu ge
Water+ Hydrogen peroxide
Stage-I
Carbin ol+ P hth alic
an h ydride
Catalyst so lu tion
Carbin ol +2,4 d iam in o-6-
ch loropyrim idin e
Stage -II
cen
Annexures GCPL 55
S tage -III: Prepar ion of Minoxidil crude
Dis t i lation
Coolin g & Centrifu ge
S tage -IV: Purifica t ion
Heatin g
Coolin g & Cen trifu ge
Man u factu rin g procedu re of Min oxid il:
Stage -I: P reparation of Urea Hydrogen peroxide adduct
Hydrogen peroxide (50%) reacts with urea to form the urea hydrogen peroxide
adduct .
Stage -II: P reparation of n -Oxide
a) The ca ta lyst solu t ion is prepared by the react ion of urea hydrogen peroxide
adduct and phtha lic anhydr ide in ca rbinol.
b) The above ca ta lyst solu t ion is added to a solu t ion of 2,4 diamino-6-
chloropyr imidine in ca rbinol and warmed. The precipita ted oxide is cooled and
cent r ifuged.
Stage -III: P reparation of Min oxid il cru de
Minoxidil crude is prepared by react ing Piper idine with stage-II a t 60-70 deg C.
Product was isola ted by cent r ifuga t ion.
Stage -IV: P u rification of Min oxid il crude
P iperid in e + Stage -II
Min oxid il cru de +
Meth an ol
Reaction m ass
Stage -III
Dryin g, m illin g , s iev in g &
packin g
Annexures GCPL 56
Minoxidil Crude pur ified by using ca rbinol to get pure Minoxidil.
23 MEBEVERINE HYDROCHLORIDE MANUFACTURING FLOWCHART:
STAGE-I:- Synthesis of 4-bromobutyl-3,4-dimethoxybenzoa te
1,4-Dibrom obu tan e
High vaccu m dis ti llation
STAGE-II: Synthesis of Mebever ine Hydrochlor ide crude
Meth yl isobu tyl
ke ton e
P otass iu m carbonate
Heat an d fi lte r
Water layer separa t ion ,
concent ra t ion
Cent r ifuge IP A. HCl
STAGE-III: Purifica t ion
Meth yl
isobu tyl ke ton e
filt er ,concent ra te and cent r ifuge
Veratric ac id +
P otass iu m
Hydroxide
1-(4-m eth oxyph en yl)-2-
e th ylam in opropan e
+
MBH-Stage -I
fi ltrate
residue
Mebeverin e
Hydroch loride Crude
Mebeverin e
Hydroch loride Crude
+activated carbon
P ackin g, Dryin g, Millin g , S ievin g
Stage -I
Annexures GCPL 57
Man u factu rin g P rocedu re for Mebeverin e Hydroch loride :
Stage -I : Vera t r ic acid reacts with 1,4-dibromocompound in the presence of
potassium hydroxide to for m the 4-bromobutyl-3,4-dimethoxybenzoa te.
Stage -II : Stage-I reacts with 1-(4-methoxyphenyl)-2-ethylaminopropane in the
presence of sodium ca rbona te in Methyl isobutyl ketone to form the
Mebever ine Hydrochlor ide crude.
Stage -III: Stage-II pur ified by Methyl isobutyl ketone to get pure Mebever ine
Hydrochlor ide.
24 TERBINAFINE HYDROCHLORIDE:
Stage -I: Terbinafine hydrochlor ide crude
Ch loro-6,6-d im eth yl-2-h epten -4-yn e
Heat, cen trifu ge
Hydroch loric ac id
cen trifu ge , dry
S tage -II: Purifica t ion of Terbinafine hydrochlor ide
Cen trifu ge , con centrate
cool, Centrifu ge
Man u factu rin g P rocedu re for Terbin afin e Hydroch loride .
Stage -I: N-Methyl –naphthyl- methanamine reacted with 1-Chloro-6,6-
dimethyl-2-hepten-4-yne in the presence of sodium carbona te in toluene to get
t erbinafine hydrochlor ide crude.
S tage -II: Stage-I pur ified by dissolving in methanol, charcolisa t ion , filt ra t ion
concent ra t ion and isopropyl a lcohol added to get t erbinafine hydrochlor ide.
N-Meth yl –n aph th yl
m eth an am in e
+Sodiu m carbon ate+ Tolu en e
Stage -II + isopropan ol +activated
carbon
s tage -1
re s idu e
Dryin g, Millin g , s iev in g
cen trifu gate
Annexures GCPL 58
ANNEXURE – III DETAILS OF STORAGE OF
SOLVENT
Annexures GCPL 59
There are no dust emissions from the plant or process operation.
The source of fugitive emission will be from the storage tank of solvents, and leakages
from reactor.
Each reactor will connected to 2-consecutive condensers for recovery of solvent residue.
The Reactors after condenser will be connected to a Scrubber of 4000 m³/hr capacity.
Solvent will be absorbed in water and water + Solvent mixture are taken to stripper to
separate the solvent and water.
All Underground tanks vent are connected through 25NB pipeline to 1m² condenser with
chilled water coolant 15°C, condensed solvent are collected in a receiver. Mixed solvent
are taken for process based on suitability.
Stored solvents are non-volatile which are having high Boiling point (>65°C) and vapour
pressure is also very less.
Annexures GCPL 60
ANNEXURE – IV WATER BALANCE &
EFFLUENT MANAGEMENT
Annexures GCPL 61
Water Balan ce Diagram
All Values are in KLD Existing [ ] Proposed ( )
Evapora tion [14.0] + (7.5) = 21.5
Waste w ate r [34.0] + (24.5) = 58.5
Evaporation [7.5] + (12.0) = 19.5
Waste w ate r [4.5] + (6.5) = 11.0
Evaporation [1.0] + (1.2) = 2.2
Waste w ate r [4.0] + (4.8) = 8.8
Tre ate d Dom e stic Se w age [4.0] + (4.8) = 8.8
P e rm e ate Re cycle d w ate r [30.5] + (24.8) = 55.3
RO Re je ct Re cycle d w a te r [7.5] + (5.9) = 13.4
[65.0] + (56.5) = 121.5
Cooling / Boiler Make-up [12.0]+(18.5) = 30.5
Process/ Floor wash / Equipment Cleaning [48.0] + (32.0) = 80.0
Domestic Consumption [5.0] + (6.0) = 11.0
Garden [4.0] + (4.8) = 8.8
ETP [38.5] + (31.0)
= 69.5
RO
SIPCOT
[27.0] + (25.8) = 52.8
ME
[3
0.5
] +
(2
4.8
) =
5
5.3
Crystalization
/ Handling /
Evaporation
0.8
[8
.0 +
(6
.2) =
1
4.2
[38.0] + (30.7) = 68.7
STP
Annexures GCPL 62
ETP Diagram – Existing
Annexures GCPL 63
ETP Diagram - Proposed
Annexures GCPL 64
Annexures GCPL 65
The process of treatment of Trade Effluent
At GCPL (Unit III), trade effluent is generated from the floor washings and
equipment cleaning. The total quantity of this trade effluent generated upon
expansion will be 69.5 KLD. Existing trade effluent of 38.5 KLD is treated in the
existing ETP/RO/MEE and reused in the process. Proposed additional quantity of
generation of trade effluent of 31 KLD will be treated in proposed ETP/RO/MEE
and reused in process.
The trade effluent generated from floor washings/equipment cleanings is
collected in a collection tank.
At the inlet of the tank, hydrated lime slurry is added to effect neutralisation.
The neutralised waste is then pumped to flow control tank, from where the
waste is allowed to discharge into a settling tank.
The overflow from the settling tank is allowed to pass through a three stage
anaerobic contact filter.
After anaerobic treatment, the waste is aerobically treated in an aerated lagoon.
The treated wastewater from the lagoon is allowed to settle in a settling tank
and is pumped to aerated lagoon II, wherein polyelectrolyte is added for better
floc formation to enable easy settling of suspended particles.
The aerated water is then taken to settling tank II, from where the clear
supernatant is pumped into the collection tank.
The treated water is then passed through the RO plant. Treated water from RO
is reused and the RO rejects are subject to Mechanical evaporation. Condensed
water from Mechanical evaporator is also reused.
Upon expansion the Domestic sewage of 8.8 KLD will be treated in STP and
reused for greenbelt development within the plant premises.
Annexures GCPL 66
ANNEXURE – IV SOLID WASTE MANAGEMENT
Annexures GCPL 67
SOLID WASTE
Sl. No. Type of Solid Waste Quantity TPA
Disposal/Treatment
Existing
1. Spent catalyst / spent carbon 2.0 Stored in HDPE Bags used for
Common Landfill-TSDF
2. Chemical sludge from waste
water treatment
0.5 Stored in HDPE Bags used for
Common Landfill-TSDF
3. Used/spent oil 0.2 Recover and Reuse-CPCB
Authorized recyclers
Proposed Expansion
1. Ash from Boiler 200 Sold to brick manufactures
2. Chemical sludge from waste
water treatment plant
3.0 Stored in HDPE Bags used for Common Landfill
3. Concentration or evaporation
residues
105 Stored in HDPE Bags used for Common Landfill
4. Process Residue and wastes 145 Stored in HDPE Bags used for Common Landfill
5. Spent Solvent 30 Authorized recyclers
Wastes from the production process are collected and stored in closed containers. The
containers containing the waste is stored in a closed shed. The waste is disposed to
common waste collection yard of Tamil Nadu Waste Management Limited at
Gummidipoondi, Thiruvallur District.
Annexures GCPL 68
ANNEXURE – VI RAW MATERIAL
Annexures GCPL 69
Raw Materials
Existing List of Raw Materials including chemicals, Catalysts & Additives
S.
No Description Total (T/Year)
1 Dextrose Mono Hydrate 500
3 Gluconic acid/Glucono Delta Lactone 2000
4 Potassium (Bi)Carbonate 12
5 Calcium Carbonate 344
6 Sodium (Bi) carbonate 42
7 Zinc Carbonate/ Zinc Oxide 18
8 Magnesium Carbonate/Oxide 100
9 Manganese Carbonate/ Oxide 6
10 Lactic acid 250
11 Calcium Gluconate 60
12 Calcium Lactobionate 15
13 Calcium Lactate 72
14 Denatured Spirit 220
15 Lactose 100
16 Boric acid 2
18 Ferrous Sulphate/Iron Powder 50
19 Orotic acid 48
20 Citric acid 400
21 Pyro Glutamic acid 15
22 L- Aspartic acid 15
23 Ascorbic acid 30
24 Glycine 10
25 Nitric acid 50
26 Calcium Nitrate 25
27 Hydrogen Per oxide 10
28 Sulphuric acid 6
29 Tri Sodium Pyro Phosphate 30
Annexures GCPL 70
Proposed List of Raw Material
Sl. No. Raw Material kgs/ Annum State
1 Ferric Chloride 4100 Solid
2 Sodium Carbonate 320 Solid
3 Sucrose 16000 Solid
4 Hydroquinone 7400 Solid
5 Sulphuric Acid 9500 liquid
6 Calcium carbonate 4800 Solid
7 Marpholine 5000 liquid
8 2-Acetyl Thiophene 4800 liquid
9 HCl 16800 liquid
10 Phenyl Magnesium bromide 1500 liquid
11 P-Formaldehyde 3000 liquid
12 Dimethyl Sulphate 500 Solid
13 Diethylamine 1200 liquid
14 4-Methylpropiophenone 2000 liquid
15 Piperidine 1700 liquid
16 1,3 dioxolone 3000 liquid
17 Epichlorohydrin 4200 liquid
18 Trisodium phosphate 11000 Solid
19 Calcium Chloride 3300 Solid
20 Magnesium Chloride 1000 Solid
21 Thiamine HCl 15000 liquid
22 Orthophophoric acid 15000 liquid
23 P2O5 15000 liquid
24 Sodium Hydroxide 21000 Solid
25 Benzoyl Chloride 9000 liquid
26 Folic acid 2000 Solid
27 Triethylamine 2000 liquid
28 citric acid 2300 liquid
29 Chlorosulphonicacid 800 liquid
30 methylne dichloride 800 liquid
31 Morpholine 400 Solid
32 Suphur 200 Solid
33 potassium carbonate 200 Solid
34 Methylbromoacetate 400 liquid
35 strontium hydroxide 200 Solid
36 malano nitrile 200 liquid
37 Nitromethane 3600 liquid
38 DMSO 2400 liquid
39 Pottasium carbonate 1800 Solid
40 Zinc dust 1500 Solid
41 Ammonia 800 liquid
42 Sorbital 2000.0 liquid
43 Dextrin 1500.0 Solid
44 N-Methyl -naphthyl methanamine 1600.0 liquid
45 Sodium bicarbonate 800.0 Solid
46 Cannamyl chloride 600.0 Solid
Annexures GCPL 71
47 Activated carbon 5000 Solid
48 Hyflo 5000 Solid
49 Nitrofurfural diactate 5400 Solid
50 Hydroxy benzohydrazide 4500 Solid
51 Dimethyl benzyl carbinol 500 Liquid
52 Dimethyl sulphate 300 Solid
53 Pottasium hydroxide 500 Solid
54 PEG-400 100 Liquid
55 Chloroacetyl chloride 200 Solid
56 2-Aminopyridine 2400 Liquid
57 Lithium 1550 Solid
58 styrene oxide 1500 Solid
59 IPA-HCl 2000 Liquid
60 2,3,4- trimethoxy benzaldehyde 3000 Liquid
61 Piperazine 1250 Liquid
62 5% palladium on carbon 1500 Solid
63 Isoproponolic acid 1800 Liquid
64 Coenzyme-Q10 1200 Solid
65 Acetic anhydride 1640 Liquid
66 N-heptane 200 Liquid
67 4-Hydroxy benzaldehyde 600 Liquid
68 Pyridine 250 Liquid
69 malonic acid 300 Solid
70 hydrogen gas 200 Gas
71 Dimethyl formamide 200 Liquid
72 Isopropalamine 300 Liquid
73 Folic acid 1200 Solid
74 sodium borohydride 600 Solid
75 Formaldehyde 400 Liquid
76 S-Phenylethyl amine 140 Liquid
77 Hydrogen peroxide 5200 Liquid
78 Urea 4550 Solid
79 phthalic anhydride 3900 Liquid
80 2,4 diamino-6- chloropyrimidine 2600 Liquid
81 Piperdine 1300 Liquid
82 Veratric acid 3000 Liquid
83 1,4 Dibromobutane 2000 Liquid
84 Potassium hydroxide 1500 Solid
85 1-2-ethylaminopropane 2000 Liquid
86 Methylisobutyl ketone 1000 Liquid
87 potassium carbonate 1000 Solid
Total RM quantity 274000 274 MT
Annexures GCPL 72
Proposed List of Raw Material – Solvents
Sl. No. Total qty of solvent Lts/ annum Storage
1 Toluene 45000 U/G
2 DMF 6000 Barrel
3 Acetone 46000 U/G
4 Hexane 12000 Barrel
5 DNS 300000 U/G
6 Methanol 800000 U/G
7 THF 12000 Barrel
8 Pyridine 8000 Barrel
9 MTBE 16000 Barrel
10 EDC 31000 U/G
11 MDC 34000 Barrel
12 Isopropanol 16000 Barrel
13 Ethyl Acetate 21000 U/G
Total 1347000
Annexures GCPL 73
ANNEXURE – VII EMISSION CHARACTERISTICS
Annexures GCPL 74
Stack Emission Characteristics (Existing) Stack No 1 2 3 4 5 6 7 8 9 10-12 13
Material of Construction S.S S.S M.S M.S M.S FRP M.S M.S FRP G.I M.S
Stack attached to Spray Drier – 1
Spray Drier - 2
3 T BOILER
D.G.Set 380 KVA
D.G.Set 180 KVA
ATFD Reactor
AHU Drier AHU Blender
AHU Exhaust
Fluid Bed Drier 120
kgs (3 Nos)
Fluid Bed Drier 120
kgs
Stack height Above the ground level in m 22.0 22.0 30.0 10.0 10.0 12.0 12.0 10.0 10.0 2.92 each 7.0
Stack top Circular/Rectangular /Square
Circular Circular Circular Circular Circular Circular Circular Rectangular Circular Rectangular Circular
Inside dimensions of the stack at top, mm 400 400 600 125 125 400 400 400 x 200 400 300 x 200 each
300
Gas quantity – m3/hr 15000 15000 19000 3200 1900 3600 3600 3600 4000 4000 2800
Flue gas temperature, oC 110 110 84 300 250 78 78 78 190 140 100
Exit velocity of the gas, m/s 20.0 20.0 22.0 12.6 16.8 10.0 10.0 10.0 9.0 9.0 6.0
Emission concentration , mg/m3
SO2 - - 13.0 55.5 50.13 - - - - 300 200
NOx - - 12.0 44.0 0.56 - - - - 95 63
SPM - - 106.0 5.0 14.5 75.0 75.0 75.0 50 140 100
Br - - - - - - - - - - -
Emission rate, g/s
SO2 - - 0.0025 0.062 0.021 - - - - 0.333 0.222
NOx - - 0.0023 0.048 0.00008 - - - - 0.105 0.070
SPM - - 0.02 0.0056 0.09 0.075 0.075 0.075 0.05 0.167 0.111
Br - - - - - - - - - - -
Annexures GCPL 75
Stack Emission Characteristics (Proposed) Stack No 1 2 3 4
Material of Construction M.S FRP FRP M.S
Stack attached to 3 T BOILER
Reactor Reactor D.G.Set 250 KVA
Stack height Above the ground level in m 30.0 12.0 12.0 10.0
Stack top Circular/Rectangular /Square
Circular Circular Circular Circular
Inside dimensions of the stack at top, mm 600 400 400 125
Gas quantity – m3/hr 16000 20000 20000 2600
Flue gas temperature, oC 140 35 35 250
Exit velocity of the gas, m/s 16.0 28.0 28.0 15.0
Emission concentration , mg/m3
SO2 - - - 52.13
NOx - - - 0.58
SPM - - - 15.5
Br - - - -
Emission rate, g/s
SO2 - - - 0.052
NOx - - - 0.032
SPM - - - 0.009
Br - - - -
Annexures GCPL 76
ANNEXURE – VIII FUGITIVE EMISSION
Annexures GCPL 77
FUGITIVE EMISSION CONTROL MEASURES
Equipment Control Measures Monitoring
Reactors Each reactor is
connected to 2-
consecutive
condensers for
recovery of solvent
residue.
The Reactors after
condenser are
connected to a
Scrubber of 4000
m³/hr capacity.
Solvent will be
absorbed in water
and water +
Solvent mixture
shall be taken to
stripper to
separate the
solvent and water.
VOC Online
Monitoring will be
installed near
Reactors at Shop
Floor.
Solvent
Storage Area
All Underground
tanks vent shall be
connected through
25NB pipeline to 1m²
condenser with
chilled water coolant
15°C, condensed
solvent shall be
collected in a
receiver. Mixed
solvent shall be
taken for process
based on suitability.
Note: Stored
solvents are non-
volatile which are
having high Boiling
point (>65°C) and
vapour pressure is
also very less.
VOC Online
Monitoring will be
installed at the
Solvent Storage
area.
Annexures GCPL 78
ANNEXURE – IX RISK IDENTIFICATION
Annexures GCPL 79
Identification of Vulnerable Areas in the Plant, and Selection of Worst Case
Scenarios
Production of API Products will involve batch process, and amount of chemicals
involved in each batch Operation is not identical. The very process itself, solvents will
not produce any excessive pressure and or temperature. As such the possibility of any
major accidents in the process per se which produce emergency situation is not
expected. Even in Reactor, which is an exothermic reaction, the temperature rise can
occur only due to cooling water failure/inadequacy or addition of excessive Solvents.
This condition can be controlled by reducing the rate of addition of solvents or
increasing the cooling water flow. Taking also into consideration the simplicity of the
process, no serious accident of that proportion that can create emergency condition is
expected. It is possible that emergency condition can be produced in the factory due to
failure of any one of the storage tank. In this case the entire quantity of solvents stored
may get released from the tank. Hence release of solvent from the storage tank has
been taken as the worst case scenario and the effect of released it to the surrounding
has been assessed using TNO’s. Effect software for dispersion.
Risk Register
Sl.
No Risk Description
What is Risk?
(Potential failure
mode)
Impact / effect of Risk (Risk
leads to)
1. Unloading Solvents Spillage of solvents,
Fire
a. Personnel safety
b. Solvent vapour inhalation
c. Ignition on static electricity
i. Leakage from the flange/ hose
joints.
ii. Accidental spillages
Overflow from the tank
2 Underground
storage tank Fire, leakages
i. Exposure of direct sunlight
ii. Solvent is transferred to tank at
high rate
iii. Leakages from tank
3
Supply from
Service tank to
Production
Leakage, line blockage
i. Heavy leakage/Line blockage/
Fracture in the pipe line.
ii. Equipment failure, flange leak
4
Personnel
Qualification &
Responsibilities
Inadequate no of
personnel, education &
training
Responsibilities not
defined or not
documented
i. Impact on the quality of product.
ii. Affects personnel safety
Annexures GCPL 80
ANNEXURE – X TOPO MAP
Annexures GCPL 81
Annexures GCPL 82