in-plant training report of ipca ratlam
DESCRIPTION
its inderdip's doucuments([email protected]TRANSCRIPT
2011
Institute of Chemical Technology, Mumbai
IN-PLANT TRAINING REPORT
Subimitte in partial fulfillment of Master ofChemical engineering.
Under the guidance of
Mr. M K MittalMr. Lokesh Khandelwal andMr. Promod Trivedi,Departmant of Environmental Health and Safety,IPCA, Ratlam
IPCA Laboratories Limited, Ratlam
ACKNOWLEDGEMENT
With a deep sense of gratitude, I, Inderdip Shere, am very thankful to my guides form the departments of Environmental
Health and Safety, Ipca, Ratlam, Mr. M. Mitthal, Mr. Lokesh Khandelwal and Mr. Promod Trivedi for their valuable guidance, suggestions and timely encouragement throughout the course
of this in-plant training. And providing me an opportunity to present the report on project Topic entitled as;
“Assessment of compliance of consent conditions, stipulation of environmental clearance and condition of
authorization under HSMD rule, 2008 for Ipca laboratories limited, Ratlam”
The completion of project would not be possible without the graceful help from all the members of EHS department in
several situations, Mr. Piyush Raj Purohit, Mr. Raj Kumar, Mr. Ravi Khelkar. There has been direct and indirect help form all
the peoples working in the industry.I would also like to thank my all colleague who have helped me to understand the subject better, without whom this work could
not have been a reality.
Date:15 June 2011Inderdip P. Shere
Final year, M. Chem. Engg.Department of chemical engineering
ICT, Mumbai
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INTRODUCTIO
NIPCA Laboratories Limited, Ratlam
Introduction
Ipca is a fully integrated, rapidly growing
Indian pharmaceutical company with a strong thrust
on exports. Ipca's APIs and Formulations produced
at world class manufacturing facilities are approved
by leading drug regulatory authorities including the
US-Food and Drug Administration (FDA), UK-Medicines and Healthcare products
Regulatory Agency (MHRA), South Africa-Medicines Control Council (MCC), Brazil-
Brazilian National Health Vigilance Agency (ANVISA) and Australia-Therapeutic Goods
Administration (TGA). With operations in over 100 countries, exports account for over
52% of the company's income.
Forbes, a leading US business magazine, selected Ipca in 2003 among its top 200
successful, rising companies outside USA, with sales under USD 1 Billion. Over 19,000
companies were considered by Forbes, and of the 18 companies from India that figured in
this list, only four were from the 'Indian Pharmaceutical Sector'. Ipca happens to be one of
them. Subsequently, Ipca was selected by FORBES in this prestigious list for two
consecutive years; 2004 and 2005. From a modest income of Rs. 0.54 crores in 1975-76, the
net income has soared to Rs. 753.30 crores in 2005-06 with exports accounting for Rs.
401.83 crores. The net profit for the year ending 31st March, 2006 stood at Rs. 63.98 crores.
Formulations constitute 67 percent of the total income for 2005-06. Today, Ipca is one of
the biggest manufacturers in the world of APIs Atenolol (Antihypertensive), Chloroquine
Phosphate (Antimalarial), Furosemide (Diuretic) and Pyrantel Salts (Anthelmintic) right
from the basic stage. Ipca is also one of the largest suppliers of these APIs and their
intermediates world over.
M/s. Ipca Laboratories Ltd. is a reputed name in the Indian pharmaceutical & Health
care industry. It is a public limited organization engaged in manufacturing pharmaceutical
products since 1975 in various plants located in India. The products made by the company
have been well received both by the national & foreign users, thereby leading to further
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expansions & developments M/s. Ipca Laboratories Ltd. had contemplated a major
expansion of its products & production capacity of the plant at Ratlam. The company has
been pioneers in development & market headers in most of the products made by them. The
plant at present manufactures 62 Bulk Drugs & is having formulation. The Existing
Production capacity of Bulk Drug is 2551.5 MT/year this consists of,
Tablet : 800 Million nos. /year
Injection : 20 Million nos. /year
Liquid orals : 2500 KL/year
Table 1: Plant over view
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Company Back Ground
One of the first modern Pharma factories of yesteryears was commissioned by IPCA
at Mumbai in 1969. The company was originally promoted by a group of medical
professionals and businessmen and was incorporated as ‘The Indian Pharmaceutical
Combine Association Limited’ in October 1949. The present management took over in
November 1975 when the total turnover of the company was just Rs. 0.54 corers. Currently,
this premise where IPCA started its operations, houses the registered office of the company,
key departments like international marketing, R&D (formulations) and analytical
development lab are located here.
IPCA is a fully integrated, rapidly growing Indian pharmaceutical company with a
strong thrust on exports. IPCA’s APIs and formulations produced at world class
manufacturing facilities are approved by leading drug regulatory authorities including the
US- food and drug administration (FDA), UK- medicines and healthcare products
regulatory agency (MHRA), south Africa – medicines control council (MCC) , brazil-
Brazilian national health vigilance agency (ANVISA) and Australia- therapeutic goods
administration (TGA). With operations in over 100 countries, exports account for over 52%
of the company’s incomes. Forbes, a leading us business magazine selected IPCA in 2003
amount its top 200 successful, rising companies outside USA, with sales under USD 1
Billion. Over 19,000 companies were considered by Forbes, and of the 18 companies form
India that figured in this list, only four were form the Indian pharmaceutical sector. IPCA
happens to be one of them. Subsequently, IPCA was selected by Forbes in this prestigious
list for two consecutive years. 2004 and 2005. Form a modest income of Rupees 0.54 cores
in 1975-76, the net income has soared to Rupees 753.30 cores in 2005-06 with exports
accounting for Rupees 401.83 cores. The net profit for the year ending 31 st march 2006
stood at Rupees 63.98 cores. Formulations constitute 67 % of the total income for 2005-06.
Today, IPCA is one of the biggest manufacturers in the world of APIs atenolol (anti
hypertensive), chloroquine phosphate (anti malarial), furosemide (diuretic) and pyrantel
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salts (anthelmintic) right form the basic stage. IPCA is also one of the largest suppliers of
these APIs and their intermediates world over.
M/s IPCA laboratories ltd, Ratlam a public limited company with share capital of
Rupees 1100 cores was established in 1984 India’s first APIs plant commissioned at Ratlam
and IPCA’s second formulations plant commissioned at Ratlam.
M/s IPCA laboratories ltd. having its registered office in Mumbai, came into
existence originally in the 1975, with a pharmaceutical manufacturing activity in Mumbai,
and gradually grown up as a large pharmaceutical corporation in coming years.
All the manufacturing operations are conducted strictly adhering to GMP norms. The
production is licensed by FDA. Batch to batch production quality control is maintained as
per he FDA rules which are the most stringent and strict amongst all the government
regulations concerning the industrial manufacturing activities.
Mission
1. Enhance continuously the total quality of life of its employees and help them realize
their potentials by
Providing opportunity to grow and realize full potential.
Improving their quality of life
Improving their skills and character
Giving joy in work / camaraderie
2. Become a key player world – wide in chosen areas of business.
3. Customer satisfaction of a high level and standards higher than that of competitors by
providing :
Quality, transparency, reliability, flexibility, cost competitiveness and enjoyable
relationship
Provide good returns to its share holders by giving
Good profitability, above average return on net worth.
Regular dividend market appreciation.
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Courteous and reliable service.
Vision
Emerge as world class player in all its chosen business areas in 5-7 years.
Achieve global standards in quality, cost, service and the scale of its operations.
Become world class in the way we thing, manage and do things using principles, methods,
systems and tools of total quality management (TQM).
The Ipca Laboratories Ltd. plant is situated in North -East direction of village
Sejavta which is approximately 7 km away from Ratlam district headquarter on the Madhya
Pradesh National Highway No. 79 connecting Mhow & Neemuch. The city of Ratlam is
situated on the main broad gauge rail route of western railway connecting Mumbai & Delhi.
It is also connected to state capital Bhopal and Rajasthan by rail. Mumbai & Kandla are the
nearest sea ports. Both are connected with rail route from Ratlam. Indore is the nearest
airport & domestic flights for Ahmedabad, Mumbai & Delhi are available from here.
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Plant Layout
Figure 1: Site Layout Plant
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Energy Consumption
With the implementation of Energy conservation measures, Ipca could still maintain
the consumption pattern, even after its expansion of production facility almost at the same
level. The energy cost as percentage of manufacturing cost has shown the decline, for year
2006-07 it was 23.69%. Which depicts the continual reduction in energy consumption due
to sustain efforts to conserve it by implementation of various energy measure and ideas to
increase efficiency of equipments. The Table below gives the comparative figure of energy
consumption of last three years.
Ipca has Energy conservational cell headed by D.G.M. assisted by Asst. Manager &
supported by 2 engineers. This team identifies various energy saving potential in different
working areas. This team makes the proposal after a brain storming session and after
evaluating its feasibility, a report is made and submitted to management for approval.
Table 2: Energy consumption
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Manufacturing process
IntroductionTo assess the possible impact of the pollutants on the environmental component, it is essential to understand the manufacturing process of the products, raw material used and nature and quantum of pollutants released during the curse of manufacturing. One may co-relate the volume and concentration of the pollutants, which is suppose to be given the treatment at pollution control facilities available at premises.
Project dataMost of the project data are process and operation related data. Project data are distinguished into project description, resources requirement (water, power, etc), technology and chemicals used, land required, and resource recovery (water, solid waste, energy, etc)
Project description
General M/s IPCA laboratories lid, located at Sejavta industrial area, Ratlam made a change in their product mix and discontinued / reduced production of certain bulk drugs and intermediates and added / increased production of certain bulk drugs and intermediates, tablets, injections and liquid orals. Total production capacity of plant is 1202 MT / year of bulk drugs, 800 millions no per year of tablets, 20 millions no/ year of injections and 2500 KL/year of liquid orals.name of product and product capacity given in Table no
S. No ProductsExisting Capacity
Additional Capacity
Total
Bulk Drugs
1. Synthetic Drug API (MTPA) 2551.5 59 2610.5
Formulations
2. Tablets (Million Nos./Year) 800 1300 2100
3. Injections (Million Nos./Year) 20 Nil 20
4. Orals (KL/Year) 2500 800 3300
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5. Dry Syrup (Million nos./year) Nil 1.5 1.5
6. Ointment (MTPA) Nil 150 150
R&D Products
7. R & D Products (MTPA) Nil 05 MT 05
Steroids & Hormones
8. Steroid & Hormonal products (MTPA)
Nil 41.391 41.391
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RESEARCH AND DEVELOPMENT
Located at Mumbai, Ipca’s research center is focused on generics in regulated
markets, specifically in Europe and USA. The center has expertise in Active
Pharmaceutical Ingredients, Drug Intermediates and Formulation Development which
includes NDDS and ANDA. Ipca’s Research and Development comprises of two sections:
1 Active Pharmaceutical Ingredient and Drug Intermediates
2. Formulation Development
Both the departments are supported by the Analytical Development cells which are
fully equipped with all modern instruments (like NMR, LC-MSMS, GCMS etc) required to
carry out research on day-to-day basis. Units are geared to continuously innovate and
remain competitive by developing/acquiring abilities to find simple and effective solutions
to practical problems, solutions which are free from Patent Infringement issues.
1. Active Pharmaceutical Ingredients/Drug Intermediates
The Active Pharmaceutical Ingredients/Drug Intermediates Research and
Development department at Mumbai is supported by two more units located at Ratlam and
Indore. All the R&D units are recognized by the Department of Science and Industrial
Research, Government of India.
Research & Development units at Ratlam and Indore are also supported by facilities
required for scale up of the processes from grams to kilo as well as to Pilot level.
Strengths:
Innovative chemistry-driven process research leading to the generation of non-
infringing routes for APIs/Drug Intermediates and Intellectual Property. Ipca has highly
qualified and experienced groups of people capable of handling patent-related issues, which
includes various aspects of patenting and patent evaluations.
Impurity Profiling of APIs:
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This includes identification and characterization as well as structural elucidation of
unknown impurities (present in APIs), followed by their synthesis.
Analytical developments:
New method developments.
Method validations for getting products registered in Regulated Markets.
Process Research:
Process development/improvements to make products competitive and profitable in
the long run by giving major emphasis on:
Non-infringing processes
Alternative cost effective routes
Increasing plant friendliness.
Improving selectivity/reducing impurity levels by sensitive chemistry inputs.
Reducing effluent generation.
2. Formulation Development
Our Formulation Development Laboratory located at Mumbai has been gearing up
for a state-of-the-art R&D facility (in line with the US-FDA requirements). The current
R&D activities are also approved by the Department of Science and Technology,
Government of India. The laboratory is well equipped with various ultramodern equipments
and technologies required for conducting high quality research activities.
Some of the equipments available in the R&D are:
High Sheer Mixer (GMP model)
Fluid Bed Drier
Fluid Bed Processor
Ganscoata
Walk-in Stability Chambers
Dissolution Apparatus with intrinsic dissolution
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Assembly
Bilayer Tablet Compression Machine
Equipments for liquid orals and semi-solid
Hard gel capsule facility
Blister packing machine with Alu-Alu facility
Press-cota
Roll compactor
Pelletisation facility
Facility for Effervescent tablets (low RH area)
Reverse laminar flow
The key activities of R&D-Formulations are:
Novel Drug Delivery System (NDDS):
R&D in this area attempts to improve the efficiency with which the medicine is absorbed in
the body. Novel
Drug Delivery Systems (NDDS) efforts are directed towards:
1. Controlled Release:
Ipca’s Research concentrates on sustained, delayed and pulsatile release. The company
introduced a novel
bilayer tablet for an antidiabetic combination.
2. Novel Dosage Formulations:
In the novel dosage form, the company concentrates on the following therapeutic segments.
Cardiac Care
Anti-infective
Anti diabetics
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Ipca’s R & D laboratory has filed patents across the world for products based on the
NDDS. Ipca’s strength in this segment of R&D puts the company in an excellent position to
compete in the growing markets for generic drugs in Europe and USA.
Abbreviated New Drug Application (ANDA):
The filing of ANDAs received a major boost after Ipca opened its wholly owned subsidiary
in New Jersey, USA. The company will now be working on ANDAs to address the growing
opportunity in USA. Ipca’s research endeavors are well supported by world class
infrastructure comprising:
Analytical Research
Clinical Research
International Regulatory Affairs
Corporate Quality Assurance
Intellectual Property Cell
Manufacturing of generic products for registration in UK/EU/South Africa/Brazil and many
other countries
At present, pollution and its abatement are a concern at every level. It is essential to
understand the magnitude of the task confronting the developing world to maintain the
cleanliness of its environment while keeping up the pace of industrialization.
While the industrial revolution brought comforts to the making in abundance, it also
brought with in miseries and discomforts, the degradation of environment, due to
industrialization, has been at an alarming pace, the increasing urban and sub –urban
population, which needed the goods in large quantities, brought with it industries in large
numbers, the Ganges of yesteryears is not the Ganges of today. The country has to cleanse
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the Ganges which was supposed to be purest in the world. As a matter of fact, not only the
Ganges, but most of the available water in the country is polluted, in addition to the
pollution of water the pollution of the air is also on rise.
Keeping the above facts in view, manufactures and entrepreneurs have no longer the
freedom to disregard to environment and they have to take every precaution to see that the
environment s not exploited in any manner. The enlightened management of the industries
has every reason to put all its might to keep the environment as pure as possible.
Communities all over the world, including India, have introduced legislations. In India, the
water (prevention and control of pollution) act was promulgated in 1974.
The other act, namely, air (prevention and control of pollution) act followed in 1981. These
tow acts aim at controlling pollution at source. The central government also promulgated a
comprehensive umbrella act, namely, environment (protection) act in 1986.
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Treatment and evaluation of the waste water management
IntroductionPrediction of impacts is the process of determining the nature and extent of the environmental changes that may result form proposed activity. The predicted value for environmental variables from the objective basis for the assessment of the environmental feasibility of the proposed activity and for evolution of the effectiveness of mitigating measures.
The management of M/s IPCA laboratories Ltd., Ratlam has decided to carry out an evaluation and performance study of exiting ETP. The study was conducted by setting up field stations for measurement of ambient air quality, meteorology, analysis of water and soil, collection demographical and other relevant data.
Table 3: pollutant sources and characteristics
S no
Activity Pollutant Pollutants characteristics
Frequency
Construction phase
1 Ground working and leveling
Air emissions –SPM, PM10, CO,NOx,SO2
Dust form construction activities and excavation. Particulates, NOx and Co form vehicles exhaust
Temporary during construction phase only- bulk of the emissions are expected from ground working and leveling activities
Earth/ solid waste
Solid waste form construction activity and excavation
Periodic
Noise Noise generated form construction equipment and machinery
Temporary during initial construction phase
2 Labor camps Sewage Sewage generated form temporary labor camps on site
Temporary- during the initial construction phase
Operation phase
1 Vehicular movement
Air emissions and noise
Vehicle exhaust emissions
Continuous / periodic
2 Diesel power generators
Air emissions SO2,NOx, SPM , CO form fuel burning
If power cut from MPSEB
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Noise Noise due to running of equipment
Continuous
3 Sewage treatment plant
Solid waste Settled and stabilized sludge
Continuous
Treated water Treated sewage used for horticulture
Continuous
4 Diesel storage Solid waste Settled sludge during tank cleaning
Occasional
Oil Oil spillage- accidental large spills due to pipe rupture oil spillage – small quantities due to small pipe leaks
Accidental / only due to poor housekeeping
5 Hydrogen bullets
Thermal / blast effect
Accidental explosion due to hydrogen leaks and fire
Accidental
6 Maintenance housekeeping
Waste water Floor washing Continuous
Solid waste Used equipment parts and garden waste
Continuous
7 Air conditioners
Air emission Ozone depleting substance release
Continuous
8 Vehicle parking area
Oil spills Minor oil leaks in parking lot
Continuous- small quantities
Water environment As stated, during operation phase, the total quantity of water is required per day for
exiting project is about 622 m3/day (622KLPD) which includes 150 KLPD of water for
utility, 250 KLPD for cooling purposes, 100 KLPD for domestic and 122 KLPD for process
purpose. Therefore total fresh water needs to be pumped is about 622 KLPD for
consumption of domestic and industrial purpose. Discharge of domestic/industrial waste
water is 350 m3/day form the exiting project, form which domestic/industrial waste waster
shall be treated in well designed effluent treatment plant. The entire volume of treated water
shall be recycled again for different uses. Part of the treated water will cover the
requirement of the cooling tower and fan coil units, which is basically the HVAC
requirement and balance water will be used for green belt development. Thus there will be
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no adverse impact over the water environment. Detail of water balance is given below in
table
Table: details of water consumption per day
1 Domestic 100 m3/day
2 Industrial a. Process 122
m3/dayb. Cooling 250
m3/dayc. Utility 150
m3/dayTotal 622
m3/day
Table: details of waste water generation per day
1 Domestic 95 m3/day
2 Industrial a. Process 122
m3/dayb. Cooling 58
m3/dayc. Utility 75
m3/dayTotal 350
m3/day
Exiting effluent treatment plant The facility has a full fledged effluent treatment plant designed for a hydraulic flow
of 500 m3/day. (Flow diagram attached)
All the effluent generated form the process plants and utilities are led to ETP through “impervious” drainage system/ the waste water form various units and streams of the plant are finally mixed together in the equalization chamber and then the composite effluent is collected into a holding tank no 1
The present effluent generation quantity is around 280m3/day
Therefore the present effluent treatment plant is adequate enough to treat the hydraulic load of waste water as per given below in table.
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Methodology of treatmentThe existing treatment process comprises of the three stages;
Primary treatment Secondary treatment Tertiary treatment
The effluent treatment is carried out in three stages
1. Primary treatment to reduce the suspended solids and BOD/COD2. Secondary treatment which is a two stage biological treatment to reduce BOD/COD3. Tertiary treatments consisting of pressure sand filter and activated carbon filter to
polish the effluent
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Primary treatmentThe composite effluent form the plant is passed through oil and grease trap to
separate the oily matter. The oil layer is periodically removed form the oil and grease trap / chamberThe oil collected in drums and incinerated in the incinerator.
The effluent is then collected in tow nos. of holding tanks operating in series. The first tank is of 300 m3 holding capacity with 3 nos. of 5 HP floating aerators, followed by another tank of 150 m3 capacity with 2 nos. of 5 HP floating aerators. The total retention time is about 22 hours. On average flow.
These tanks serve the purpose ofa. Equalization of effluent feed stream.b. Stripping of volatile organicsc. Mixing of neutralizing chemicals
The neutralized effluent is then pumped to the chemical treatment tank where a coagulant dose, alum or PAC or ferric chloride is added. It is then passed into a primary clarifier to facilitate settlement of flocculated mass for better flocculation polyelectrolyte is also added. The primary sludge settled at the bottom of clarifier is taken into sludge drying beds for drying, while the clarified effluent is further subjected to biological treatment.
Secondary treatmentThe biological treatment provided is a tow stage extended aeration activated
sludge process. The residence period in the total system is 3 days and oxygen supplied is 2400 kg/day by means of 98 HP surface aerators.
The clarified effluent form the 1at stage clarifier is taken to an intermediated sump for pumping to the 2nd stage aeration tank. In the secondary aeration tank BOD and COD is further reduced.
The secondary sludge form both the secondary clarifiers is recycled in their respective aeration tanks or taken to the sludge drying beds for drying.
Tertiary treatmentTertiary treatment facility at the plant comprises of following units
I. Pressure sand filterII. Activated carbon filter.
The clarified effluent form second stage secondary clarifier passes through pressure sand filter. In the sand filter fine suspended matters and colloidal matters are removed.
The quality of the biological oxidized effluent is slightly higher the standards prescribed. Hence it is further taken for tertiary treatment by passing through
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activated carbon to remove traces of organics. This will act as a polishing treatment to the biologically oxidized effluent.
Further carbon adsorption helps in removal of the refractory organic compounds in the waste water.
Effluent the tertiary treatment, the effluent passes through a holding sump provided with V- notch. It is then pumped to the holding lagoon located at the dairy farm through a closed pope line for final disposal. Ultimately the treated effluent is disposed off either by solar evaporation or use for irrigation purposes.Form quality of treated waste water it is observed that it is meeting the discharge norms of MPPXB for treated effluent. Even the yield of the various crops like maze, wheat and sugarcane etc. taken form this water is quite good.
Table 4: details of units of effluent treatment plant
S no
Unit Size (m)
Volume (m3)
Hydraulic retention time
1 Oil separator (2 no) 5 *1.2*1(SWD)
6 1 hours on average flow
2 Holding point (2no0 with floating aerators / mixers
12.5(D)*2.5 (SWD) *3
300/150 22hours
3. Chemical treatment tank with slow mixer
2.5 *2.5M*2.0M SWD *3 nos.
12.5 0.5hours
4 Primary clarifier 7 (diameter) *2.6 (SWD)
100 4hours
5 Bio reactor no 1 with surface aerators
9.25 *18.5 *3(SWD) +1.0
1000 1.5 days
6 Bio reactor no 2 with surface aerators
18.5 *18.5*3(SWD) +1.0
500 1.5 days
7 Secondary clarifiers 1 and 2 7 (diameter) *2.6 (SWD)
100(each) 4 hours
8 Intermediate effluent 2.6(diameter) *2 (SWD)
10 -
9 Sludge drying beds 10 *10*3 300 6 days10 v-notch chamber 1.55 *0.8*0.8 0.96 -11 Lagoon Bottom
(71.5*49.2)Top (85*62.5*4.3)
- -
12 Sand filter 0.3 *1.5*3nos 13 Activated carbon filter
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Table 5: details of the mechanical equipments
S no
Equipment Hp Make Purpose
1 Intermediate effluent pump
5 KIRLOSKAR Pumping effluent form intake well to oil separator
2 Return sludge pump
5 CROMPTOM GREAVES/RADICON
3 Floating aerator 5 CROMPTOM GREAVES/RADICON
Attaching to holding tank
4 Mixer 3 KIRLOSKAR Chemical treatment tank
5 Surface aerator (4 no)
15 KIRLOSKAR Bioreactor tank
6 Primary clarifier 2 CROMPTOM GREAVES/RADICON
7 Secondary clarifier 2 CROMPTOM GREAVES/RADICON
Sewage treatment plant All the sanitary discharges are diverged to STP via drains and sewage discharges are collected into a septic tank. Septic tank overflow is transferred to the bio reactors where it acts as a nutrient for bio mass development. There is no direct discharge of sanitary and sewage waste water on surface water bodies of possibility ground water contamination.
Waste water characterization To carry out a systematic performance analysis of the existing effluent treatment plant, it was decided to collect the samples from all the units of the plant.All the results are complied in enclosed table and are as follow.
Sampling date Following are the average analysis data of the samples.
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Table 6: average analysis data of the samples
Parameter
Outlet of equalization tank (holding tank)
Outlet of chemical treatment tank
Outlet of primary clarifier
Secondary clarifier 1
Final tank
Bioreactor
1 2pH 7.5 8.53 7.44 7.405 8.52BOD 1660 1660 8.42COD 5110 5110 3057 1318 32.38
5TS 4931 4931 0TDS 4678 4678 0TSS 253 253 56.2 0MLSS 337
53626.77
Design basis and details of the exist ion ETP1. Raw waste waster characteristic:- the average characteristics of the raw waste
water has been found as below:
Flow 500 m3/daypH 6.5-10.5BOD 800-2000COD 2300-5000TS 1200-9800TDS 1000-9000TSS 200-800O&G 20-40
2. The effluent treatment plant consists of the following units
Oil and grease trap
No of traps 2 nosDimensions 5M*1.2M*1M SWD
*2nosMaterial of construction
RCC tank with polyurethane coating
Retention time 1 hour on average flowVolume 6m3(each)
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Holding pond
Holding ponds 2 no’sMaterial of construction
it is RCC tank provided with polyurethane coating
Volume 150 m3/300 m3Dimensions 12.5 m diameter *2.5 MSWD*3NosRetention time 22hours on average flow
These tanks are be provided with floating aerators / mixers for mixing and equalization of effluent
Chemical treatment tank
Volume 12.5m3
Material of construction
RCC tank with polyurethane coating
Retention time 0.5 hour on average flowDimensions 2.5M*2.5M*2.0M SWD
*3nosThe tank provided with slow speed mixer. These mixers are also help in effective neutralization of effluent during addition of neutralizing chemicals.
Primary clarifier
Volume 100 m3
Dimensions 7M diameter *2.6M SWD
Retention time 4 hour on average flow (20 hours)
Material of construction RCC tank
Sludge drying beds
Chemical sludge 200 kg/dayDrying period 6 days
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Produce per day % consistency
2.0%
Material of construction
brick masonry construction provided with 600 mm height filter media
Volume 12.5m3
Drying bed area 200 m2
Dimensions 10 M*10*2 no’s
Bio reactorTotal BOD load 1500 kg/dayBOD load after primary treatmentBOD loading (F/M)I stage 0.3II stage 0.15MLSS concentration 4000-4500 PPMOxygen requirement 2.0 kg of O2 / Kg of BOD appliedVolume of bio reactorI stage 1000m3
II stage 500 m3
Retention time (overall) 3.0 days (approx)DimensionsBio reactor no I 9.25 M*18.5 M*3.0M SWD +1.0 MBio reactor no II 18.5 M*18.5 M*3.0M SWD +1.0 MHP required for oxygenation90 HPMaterial of construction these are RCC tank, provided with RCC Bridge for installation of surface aerators.
Secondary clarifiersNo of tanks 2 no’sVolume 100 m3 (each)Retention time 4 hours on average flowDimensions 7M diameter *2.6 M SWDMaterial of construction RCC tank
Intermediate effluent sump
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Function to pump the 1st stage clarified effluent to 2nd stage aeration tank
Volume 10 m3
Dimensions 2.6 M diameter *2.0 M SWDMaterial of construction RCC tank
Sludge drying beds% consistency 1.0%Drying period 6 daysDrying bed area 300 m2
Dimensions 10 M*10*3 no’sMaterial of construction brick masonry construction provided with 600 mm height filter media
V-notch chamberThis chamber is provided with a V- notch to measure the out going flowDimensions 1.5 M*0.8 M * 0.8 M Material of construction brick masonry /RCC
Lagoon The effluent water is being stored in the lagoon is given appropriate physical and chemical treatmentDimensions bottom diameter 71.5 M* 49.2 M
Top diameter 85 M* 62.5 M *4.3 MMaterial of construction brick masonry /PCC lining
Sand filterNo 1 Size 0.3 M * 1.5 M * 3Capacity for 80 m3/day is sufficient for sand filter and activated carbon filter
Activated carbon filterNo 1Size 0.3 M * 1.5 M * 3Capacity for 80 m3/day is sufficient for sand filter and activated carbon filter
Analysis and observation of the existing ETPDesign basis
In-plant training, IPCA, Ratlam Page | 30
Supplier has taken the values at higher side considering the changes that may occur with the time span
Flow 350 m3/day
pH 6.5-10.5BOD 1500COD 5000TS 5000TDS 4500TSS 500O&G 50
Considering is to be continuous process has been applied 1. Oil separator
Design flow taken as 6.0 m3/dayRetention time then 1 hour (remark) (OK)
2. Holding pond
Design flow taken as 150 m3/day
Retention time then 22 hours (remark) (ok)
3. Chemical treatment tankDesign flow taken as 12.5 m3/dayRetention time then 0.5 hours (remark) (OK)
4. Primary clarifierDesign flow taken as 100 m3/dayRetention time then 4 hours (remark) (OK)
5. Bio reactorBOD load 1500kg/dayBOD loading (F/M)
I stage 0.3II stage 0.15
MLSS concentration 4000-4500 PPMOxygen requirement 2.0 kg of O2 / kg of BOD applied (remark) (OK)For tank volume of 1000/500 m3 the MLSS and F/M ratio is within design parameter
6. Secondary clarifierDesign flow with 100% re-circulation 100 m3/dayOver flow rate 16m3/m2/dayRetention time 4 hours
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The oil and greases content has reduced form 130 – 150 mg/l to 16 -20 mg/l at primary oil separatorsThe effluent equalizes over the organic load due to proper mixing and the volatile matter is also removed by stripping of solvent traces giving substantial reduction in COD levels reveals proper functioning of aeration grid and sprinkler nozzles in equalization tank Introduction of more effective coagulants like FeSo4 and poly electrolyte in neutralization tank The reduction in the COD concentration in the primary stage has been observed as 35- 40 %Better bacterial grow this observed and the DO levels have increasedThere is no accumulation of the activated biomass and the entire bio mass is available for recirculation in secondary settling tank Pressure sand filter and activated carbon filter has helped in the tertiary treatment in maintaining the outlet norms
Suggestion and recommendation on performance of existing ETP The existing ETP at EPCA, Ratlam has been over designed. The parameters as analyzed before treatment is of very high concentration but after treatment at the ETP all the parameters falls within the prescribed limits of MPPCB. For better functioning of the ETP, the following suggestions are advisable1. Dosing at neutralization tank can be minimized, if proper dosing calculation
can be done.2. Oil removal system can be made more effective if proper skimming of the
floating oil is made from time to time3. Quantity of lime dosing to be properly calibrated to reduce lime sludge4. Design MLSS to be maintained at the aeration tank 5. DO level to be monitored at the aeration tank \sludge level to be monitored at
the secondary settling tank 6. Proper backwashing of the PSF and ACF to be done to obtain maximum
efficiency.7. RO treatment can be used for reduction of TDS of the final treatment effluent
for further use.
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PERFORMANCE EVALUATION OF THE INCINERATOR
INTRODUCTION
Prediction of impacts is the process of determining the nature and extent of the environmental changes that
may result from proposed activity. The predicted values for environmental variables from the objective
basis for the assessment of the environmental feasibility of the proposed activity and for evaluation of the
effectiveness of mitigating measures.
DESIGN BASIS AND DETAILS OF INCINERATORS
1. Waste Data
Composition Solid ( % by weight) Liquid ( % by weight)
Chlorides 1.6 6.3
Phosphorous 1.7 6.9
Carbon 32.1 33.03
Hydrogen 5.06 5.16
Sulphur 0.23 0.40
Oxygen 35.88 60.2
Nitrogen Traces Traces
Ash 26.73 1.21
Calorific value ( Kcal/kg) 1817 9664
2. Area Classification : Non Hazardous
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Duration for operation : 20 hrs per day
3. Utility Specification
Fuel LDO
Instrument air 6-7 kg/cm3 9g) dry, oil and dust free
Process Water 2 kg/cm2 (g) at ambient
Alkali Solution 5% NaOH
Power
Motor
Instrumentation & Control
440 V, 3 phase, 50 Hz
230V, 3 phase, 50 Hz
4. System Parameters
A. Solid waste Incinerator
Type Pyrolytic with primary and secondary
chambers
Thermal Capacity 710000 Kcal/Hr
Operating Temperature
Primary
Secondary
750-850 oC
950-1150 o C
Operating Pressure -5 to -15 mm WG
Auxiliary Fuel LDO
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Firing Rates (Kg/Hr) 100 (Kg/Hr) solid waste
Mixing Firing 50 (Kg/Hr) liquid waste
Duration 10 hrs/day
B. Quench
Type Open Spray type
MCC Acid resistant refractory
Flue gas inlet temp 500 oC
Flue gas outlet temp. 50oC
Quench Field Water
C. Absorption Tower ( Packed Coloum)
Type Vertical Cylindrical randomly packed
MCC MSRL
Type of Packings PP Intallox sadddie
Scrubbing Media 5% Alkali Solution
D. Stacks
Type Self Supported
Diameter 400 mm at top
Height 30 mtrs
MOC MSRL
E. Combustion cum Dilution Air Fan
Type Centrifugal
MOC MS
Capacity 6000 M3/hr
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Head 150 mm WG
Motor 7.5 HP
F. I/D Fan
Type Centrifugal
MOC MS
Capacity 7500 M3/hr
Head 400 mm WG
Motor 25 HP
G. Fuel Oil Tank
Type Horizontal Cylindrical
MOC MS
Capacity 1 M3
H. Recirculation Pumps
Type Centrifugal
MOC UHMW
Capacity 25 M3/hr
Head 3 kg/cm2 (g)
Motor 10 HP
I. Plate Heat Exchanger
Type Plate type
MOC Titanium
Thermal capacity 5,30,000 Kcal/hr
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Cooling Water Inlet temp – 32 0C
Outlet temp – 38 0C
PERFORMANCE EVLUATION FOR INCINERATOR
1. Burner installed on the unit is of pre jet type with following specification:
Capacity : 3.00 LKcal/Hr X 2 nos.
Fuel : LDO
Comment (A) Both the burners are found in working condition with satisfactory performance.
(B) Combustion Was Colourless
(C) Sensor working properly
2. Stack Temperature found to be in range of 60-80OC, which is as per recommended practice.
3. Refractory lining checked and found to be OK
4. Fuel filter and pressure gauge were working properly.
5. ID fan and FD fan is working properly.
6. Safeties & Control of the unit(A) Bypass Damper opening in case of power failure(B) Combustion parameters at the outlet of the unit were checked & found OK
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7. Client has installed and Heat recovery unit at the flue gas outlet of the incinerator, which shows the concern of the user to prevent the losses & save the environment.
8. Performance of Incinerator is 99%.
SUGGESTION & RECOMMENDATION1. Timely overhauling and replacement of burner is needed attention.
2. Regular maintenance is to be scheduled for refractory lining.
3. Confirmation required with the design parameters towards the pressure drop across the heat exchanger is in
line with the safety limits of the fans.
4. Further safety devices like flame failure, auto ignition, fuel pump for low and high pressure, charging door
open interlocking are recommended of better performance of the incinerator.
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Environment health and Safety
EHS Management system
Environment, Health, Safety (EHS) program is managed according to the framework that sets out consistent standards of employee health and safety, environmental protection and sustainability. This framework acts as an internal regulatory system that reflects our understanding of risks to ensure our operations comply with laws and regulations. Our integrated EHS management system is further evaluated on a regular basis to identify areas for continual improvement.
By thoroughly tracking our performance, we are able to spotlight our successes in eliminating or reducing our EHS impacts, quickly and responsibly handle any EHS issues, and identify key areas where we need to focus on improving our performance.
During the past few years, Ipca has improved energy efficiency and reduced the emissions in various operations. Our strategy is to focus on continuous improvement by striving to learn from our experience and those of others, and to apply scientific, economic and technical analysis to adopt best practices.
Environment management system
To achieve sound environmental performance, organizational commitment towards a systematic approach and continual improvement of its all aspects arising out of all its activities is a pre- requisite.
They have made an inventory of all activities, which are interfacing with environment and have positive of negative impact. To mitigate the adverse effect of all such activities documented procedures are implemented by trained persons. Wherever required “environment management procedures” are made to mollify the adverse effects of the industrial activities. Management review is done periodically of EMS and preventive measures are decided and implemented
Experience of last few months after implementation of EMS cam be narrated in the following few words.
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Environment policy
IPCA laboratories Ltd .Ratlam is committed to create and maintain clean, safe and pleasant working environment. They used to do continual improvement for pollution control over and above abiding all environmental legislation and regulations.
They have taken initiation for energy and water conservation, waste reduction and other objectives, keeping in view the interest of employs and associates. They give averseness training to employs, contractors and the concerned vendors.
What is pollution?
The air, water, soil, plants and animals – all constitute the environment. These constituents keep on interaction with each other to maintain a mutual balance, called ‘ecological balance’. Man, using nature in the process of development does cause certain changes in environment. It these changes are not fully orchestrated to preserve the harmony of nature and the ecological balance, he runs the risk not only of increasing the costs of development but also of imbalances which may be so serous as to reduce his living conditions instead of enriching them. It is this imbalance which creates pollution.
Industrialization and pollution
Industries have often been called “the big polluter”. The impact on human environment is not restricted to highly industrialized countries only. India also has severed pollution problems of its own. Improper location of industries, the use of ‘polluting’ technologies, and inadequate waste treatment facilities are mainly responsible for deterioration of air and water quality in industrialized cities of our country.
There is a growing need for industrialization and more important is to preserve and world for improvement of environment and ecology. IPCA laboratories ltd. Ratlam has given equal importance to both
Following steps have been taking to preserve and enrich the environment and ecology at IPCA laboratories lid, Ratlam 1. Technology selected which is less pollution.2. Training people and creating full awareness in this direction.3. pollution controls considered a social need in place of legal requirement 4. Integrated facility for effluent treatment and incinerator and its monitoring 5. Extensive tress plantation.
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Formulation of check list as per concerning environmental acts
Hazardous Waste (Management and Handling) Rules, 1989Order Rules Rules
citationChecked
1 Responsibilities of the occupier for handling of Hazardous wastes
4
1.1 Is Hazardous wastes generated is sent or sold to a recycler of re-processor or re-user registered or authorized?
Sub rule 2 Yes/ No
1.2 Is hazardous wastes transported in accordance with the provisions of these rules
Sub rule 3 Yes/ No
1.3 Is facility to the treater provided as per state pollution control board? Sub rule4 Yes/ No
2 Grant of authorization for handling hazardous wastes 52.1 Is it authorization from the State pollution control board? Sub rule 1 Yes/ No2.2 Is application in Form 1 made to state pollution control board for
authorization?Sub rule 3 Yes/ No
2.3 Is authorization in Form 2 obtained from State pollution control board?
Sub rule 4 Yes/ No
2.4 Whether authorized person who is handling Hazardous wastes maintaining record in Form 3?
Sub rule6 Yes/ No
2.5 Is prepared record is submitted to State pollution control board as specified in Form 4, before 30th of June?
Sub rule6 Yes/ No
2.6 Is application for renewal of an authorization in made in Form 1? Sub rule7 Yes/ No
3 Storage of hazardous waste 73.1 Is record of sale, transfer, storage, recycling and reprocessing of
Hazardous waste is maintained?Sub rule1 Yes/ No
4 Procedure for grant of registration 84.1 Is application in Form 5 for recycling or reprocessing of hazardous
waste is made?Sub rule1 Yes/ No
4.2 Is consent to establish granted by the State pollution control board attached?
Sub rule1 (a) Yes/ No
4.3 Is certificate of registration issued by the district industries center or any other government authorized agency, attached?
Sub rule 1 (b) Yes/ No
4.4 Proof of installed capacity of plant and machinery is attached? Sub rule 1 (c) Yes/ No4.5 Is certificate for compliance of effluent, emissions standards and
treatment and disposal of hazardous wastes, is attached for renewal?Sub rule 1 (d) Yes/ No
4.6 Is records of hazardous wastes purchased and processed is maintained?
Sub rule 2 Yes/ No
4.7 Is the records is filed in annual return of its activities to state pollution control board on 30th June of every year?
Sub rule 7 Yes/ No
5 Do we sell hazardous wastes to the occupier having valid registration from central pollution control board for recycling or recovery?
9 Yes/ No
6 Is utilization of hazardous wastes is processes is approved by central pollution control board?
11 Yes/ No
7 Treatment, storage and disposal facility for hazardous wastes 187.1 Is the design and setup of treatment storage and disposal facility as
per technical guidelines issued by the central pollution control Sub rule 2 Yes/ No
In-plant training, IPCA, Ratlam Page | 41
board?7.2 Is the storage and disposal facility is operated as per the guidelines
issued by the central pollution control board?Sub rule 4 Yes/ No
7.3 Is record for treatment, storage and disposal facility of hazardous wastes is maintained?
Sub rule 5 Yes/ No
8 Packaging and labeling 198.1 Is packaging and labeling for safer handling, storage and transport is
as per the guidelines issued by the central pollution control board?Sub rule 1 Yes/ No
8.2 Is labeling and packaging is easily visible and could sustain physical conditions and climatic factors?
Sub rule2 Yes/ No
9 Transportation of hazardous waste 209.1 Is transportation of hazardous wastes as per rules of motor vehicles
act, 1988?Sub rule1 Yes/ No
9.2 Is in formation regarding hazardous wastes and an emergency measure is provided to the transporter in Form 11?
Sub rule2 Yes/ No
9.3 Is hazardous waste containers are marked as per Form 12? Sub rule2 Yes/ No9.4 Whether the ‘No objection certificate’ from State Pollution Control
Board of both the states (from and to) is obtained?Sub rule3 Yes/ No
10 Manifest system (movement of document to be used within the country only)
21
10.1 Is 6 copies of manifest in Form 13 prepared as per the rule Sub rule 1 Yes/ No10.2 Is copy 1 (white) is forwarded to state pollution control board? Sub rule 2 Yes/ No10.3 Is copy (blue) is received from operator on completion of treatment? Sub rule 5 Yes/ No
11 Records and returns 2211.1 Is a record of operations of facility for disposal of hazardous waste is
maintained in Form 3?Sub rule 1 Yes/ No
11.2 Is annual returns is sent to state pollution con troll board in Form 4? Sub rule 2 Yes/ No
12 Accident reporting and follow up 2412.1 Is report of accident dealing with hazardous wastes, if any, is
submitted to state pollution control board in Form 14?24 Yes/ No
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The manufacture, storage and import of Hazardous chemical rules, 1989Order
Rules Rules citation Checked
1 Approval and notification of sites 71.1 Is it approved for undertaking of industrial activity? Sub rule 1 Yes/
No1.2 If any changes are made in the activity, has it been reported to
concerned authority?Sub rule 2 Yes/
No
2 Safety reports and safety and reports 102.1 Has safety report on the industrial activity in concern of authority is
submitted to concerned authority?Sub rule 3 Yes/
No2.2 Has safety audit with the help of an expert is performed? Sub rule 4 Yes/
No2.3 Is auditor’s report is been forwarded with comments to concerned
authority, with in 30 days after completion of audit?Sub rule5 Yes/
No2.4 Is the safety audit is updated every year and same is submitted with
comments to concerned authority?Sub rule 6 Yes/
No
3 Updating of reports under rule 10 113.1 Whether the modification to the industrial activity is made to which
safety report is applicable, if so, modification in the report is sent to concerned authority, before 90 days of modification?
Sub rule1 Yes/ No
3.2 If industrial activities are unchanged with respect to the safety report, then, has further report is being send within 3 years?
Sub rule 2 Yes/ No
4 Preparation to on-site emergency plan by the occupier 134.1 Is up-to date emergency plan is made to deal with major on site
accidents as per schedule II?Sub rule1 Yes/
No4.2 Whether plan includes the name of the persons who are responsible
for safety?Sub rule1 Yes/
No4.3 Whether changes in plans are being informed to relevant provisions? Sub rule 2 Yes/
No4.4 Whether mock drill on the on-site emergency plan is conducted every
6 months?Sub rule4 Yes/
No4.5 Is detailed report of the mock drill conducted is made available to the
concerned authority?Sub rule5 Yes/
No
5 Information to be given to persons liable to be affected by a major accident
15
5.1 Whether appropriate steps are taken to inform persons who are likely to be affecting by the major accident?
Sub rule1 Yes/ No
6 Collection, development and dissemination of information 176.1 Whether safety data sheet is developed as specified in schedule 9 and
could be accessible upon request?Sub rule 2 Yes/
No
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6.2 Whether safety a data sheet includes accurate information related to hazardous wastes and added to material safety data sheet as specified in schedule 9?
Sub rule 3 Yes/ No
6.2 Whether every container of a hazardous chemical is labeled or marked as per the rule?
Sub rule 4 Yes/ No
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The Hazardous wastes (management, handling and Trans boundary movement) rules, 2008
Order
Rules Rules citation Checked
1 Responsibilities of the occupier for handling of hazardous wastes
4
1.1 Whether the hazardous wastes are sent to an authorized re- processor? Sub rule 2 Yes/ No
1.2 Whether the waste sent for reprocessing or recycle thing is being transported accordance with the provisions of the rules?
Sub rule3 Yes/ No
1.3 Whether all adequate steps are taken while handling hazardous wastes as per the rule?
Sub rule Yes/ No
2 Grant of authorization for handling hazardous waste 52.1 Do we have obtained an authorization from the state pollution control
board for handling hazardous wastes?Sub rule1 Yes/
No2.2 Are the handling of hazardous wastes is done in the facilities, which
are authorized by the state pollution control board?Sub rule 2 Yes/
No2.3 Whether the application in Form 1 to the state pollution control board
is made for the authorization?Sub rule3 Yes/
No2.4 Whether the record of waste handled by each authorized personal
made in Form 3?Sub rule4 Yes/
No2.5 Whether the annual return is submitted to state pollution control
board containing the details specified in Form 4 on or before 30th of June?
Sub rule4 Yes/ No
2.6 For renewal of authorization whether application is made in Form 1? Sub rule7 Yes/ No
2.7 Whether all the possible steps take to reduce and prevent waste generation with condition specified in the authorization?
Sub rule8 Yes/ No
3 Storage of hazardous waste 73.1 Whether the record is maintained for storage of hazardous waste as
per the rules?Sub rule1 Yes/
No3.2 Whether the storage time is as per rules Sub rule1 Yes/
No
4 Procedure for grant registration 84.1 Whether the application in Form 5 made for recycling or
reprocessing the hazardous waste as per Schedule IV?Sub rule1 Yes/
No4.2 Whether the application is accompanied by the copies of documents
listed in the rules for grant or renewal of registration?Sub rule1 Yes/
No4.3 Whether the record of re-processed is maintain in Form 6? Sub rule7 Yes/
No4.4 Whether annual return of the activities of previous year is made to
state pollution control boards or pollution control committees?Sub rule7 Yes/
No
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5 Whether hazardous wastes are sold to recycler having a valid registration from the central pollution control board for recycling or recovery?
9 Yes/ No
6 Whether the recycling, if any, is as per guidelines issued by the central government and central pollution control board?
10 Yes/ No
7 Treatment, storage and disposal facility for hazardous waste 187.1 Whether the treatment storage and disposal facility is as per technical
guidelines issued by the central pollution control board?Sub rule2 Yes/
No7.2 Whether storage and disposal facility and its closure and post closure
phase are as per guidelines issued by the central pollution control board?
Sub rule4 Yes/ No
7.3 Whether the records of hazardous wastes handled is maintained in Form 3?
Sub rule5 Yes/ No
8 Packaging and labeling 198.1 Whether the package and labeling is as per the guidelines issued by
the Central pollution control board?Sub rule1 Yes/
No8.2 Is labeling and packaging is easily visible and would be able to
withstand physical condition and climatic factors?Sub rule2 Yes/
No
9 Transportation of hazardous waste 209.1 Is transportation of wastes is as per the provisions of the rules made
by the central government under the motor vehicles act, 1988?Sub rule1 Yes/
No9.2 Whether the relevant information in Form 11 is provided to the
transporter?Sub rule2 Yes/
No9.3 Whether the container is marked the hazardous wastes as per Form
12Sub rule2 Yes/
No9.4 Whether ‘No Objection Certificate’ is obtained from the state
pollution control board?Sub rule3 Yes/
No
10 Manifest system (movement of document to be used within the country only)
21
10.1 Is 6 copies of manifest in Form 13 prepared as per the rule Sub rule 1 Yes/ No
10.2 Is copy 1 (white) is forwarded to state pollution control board? Sub rule 2 Yes/ No
10.3 Is copy (blue) is received from operator on completion of treatment? Sub rule 5 Yes/ No
11 Records and returns 2211.1 Is a record of operations of facility for disposal of hazardous waste is
maintained in Form 3?Sub rule 1 Yes/
No11.2 Is annual returns is sent to state pollution con troll board in Form 4? Sub rule 2 Yes/
No
12 Accident reporting and follow up 2412.1 Is report of accident dealing with hazardous wastes, is any, is
submitted to state pollution control board in Form 14?24 Yes/
No
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The Noise Pollution (Regulation and Control) Rules, 2000Order
Rules Rules citation Checked
1 Ambient air quality standards in respect of noise fro different areas/ zones
3
1.1 Whether the ambient air quality with respect to noise is as per schedule?
Sub rule 1 Yes/ No
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The Bio Medical Waste (Management and Handling) Rules, 1998Order
Rules Rules citation Checked
1 Duty of occupier 41.1 Whether all steps are taken to ensure that such waste is handled
without any adverse effect to human health and the environment?4 Yes/
No
2 Treatment and disposal 52.1 Whether the treatment and disposal of the waste is as per schedule I
and with compliance with the standards prescribed in schedule V?Sub rule1 Yes/
No2.2 Whether a waste treatment facility is set up in accordance with the
Schedule VI?Sub rule2 Yes/
No
3 Segregation, packing, transportation and storage 63.1 Whether the bio medical waster is collected separately? Sub rule1 Yes/
No3.2 Whether the bio medical waste is segregated into the containers/ bags
in accordance with Schedule II?Sub rule2 Yes/
No3.3 Are the container labeled according to Schedule III? Sub rule2 Yes/
No3.4 Is all of the bio medical waste is treated before the period of 48 hours,
or permission is taken from the authorized person, subjected it does not affect the human health and environment?
Sub rule 5 Yes/ No
4 Authorization 84.1 Is application in Form 1 for grant of authorization is made? Sub rule 2 Yes/
No4.2 Whether the application is accompanied by a fee as prescribed by the
government of the state?Sub rule3 Yes/
No
5 Annual report 105.1 Whether the annual report is submitted to the authority in Form 2 by
31st of Jan?10 Yes/
No
6 Maintenance of records 116.1 Whether the records related to the generation, collection, reception,
storage, transportations, treatment, disposal or handling is maintained?
Sub rule 1 Yes/ No
6.2 Are records are ready for inspection and verification by the authority at any time?
Sub rule2 Yes/ No
7 Accident reporting 127.1 Whether the report in Form 3 for accident is submitted to the
concerned authority?12 Yes/
No
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The Air (Prevention and Control of Pollution) Act, 1981(Act No. 14 Of 1981)
Order
Acts Acts citation Checked
1 Restrictions on use of certain industrial plants 211.1 Whether the establishment of operation of an industrial plant is with
the consent of the state government, in an air pollution area?Sub act 1 Yes/
No1.2 Whether the application for consent of the state board is accompanied
by fees?Sub act 2 Yes/
No
The Air (Prevention and Control of Pollution) Rules, 1982The Air (Prevention and Control of Pollution) (Union Territories) Rules, 1982
Order
Rules Rules citation Checked
1 Form of application for consent and fees 9 (chapter IV)
1.1 Whether the application for consent is made in Form 1? Sub rule 1 Yes/ No
1.2 Whether the prescribed application fee is paid as per the rule? Sub rule 1 Yes/ No
2 Manner of taking samples 12Yes/ No
2.1 Whether the required facilities are provided for taking samples of air or emission as may required by the board or empowered officer?
Sub rule 1 Yes/ No
3 Form of appeal and manner of preference 17Yes/ No
3.1 Is appeal under section 31 against an order passed by the board, if any, is filled in the Form 7?
Sub rule 1 Yes/ No
3.2 Is appeal is as per the rule? Sub rule 3 Yes/ No
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The Water (Prevention and Control of Pollution) Act, 1974Act No 6 Of 1974
The Water (Prevention and Control of Pollution) Rules, 1975Order
Rules Rules citation Checked
1 Application for consent 321.1 Is application of consent in Form 13 made to central board? 32 Yes/
No
2 Directions 342.1 Whether all direction issued in writing, if any, have been followed in
time span of 15 days?Sub rule 3 Yes/
No
The Waste (Prevention and Control of Pollution) Cess Act, 1977(Act No. 36 Of 1977)
Order
Acts Acts citation Checked
1 Levy and collection of Cess 31.1 Is levy and collection of Cess is as per Schedule II? Sub Act2 Yes/
No1.2 Is levy and collection of Cess applicable to us? Sub Act 2 Yes/
No
2 Whether the meters are affixed as per the act? 4
3 Furnishing of returns 53.1 Whether returns are being furnished? Sub Act 1 Yes/
No
4 Rebate 74.1 Whether we are entitle for the rebate of Cess as per Act? 7 Yes/
No
The Water (Prevention and Control of Pollution) Cess Rules, 1978Order
Rules Rules citation Checked
1 Standards of the meters and places where they are to be affixed
3
1.1 Are Vee notches are permitted from authority? Sub rule 2 Yes/ No
1.2 Is separate meter is affixed to measure the purpose as per Schedule II Sub rule 3 Yes/
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No1.3 Are meters approved by the assessing authority and is as per the rule? Sub rule 4 Yes/
No
2 Furnishing of returns 42.1 Is the return is furnish in Form I on or before 5th of every month? Sub rule 1 Yes/
No
3 Manner of payment of the Cess to the central government and the time within which it shall be paid
5
3.1 Is Cess amount remitted in bank draft as per mentioned rules? Sub rule 2 Yes/ No
4 Appeal 94.1 Whether aggrieved by an order of assessment under section 6 or order
imposing penalty under section 11?Sub rule1 Yes/
No4.2 Whether the appeal in Form II made, as per the rules? Sub rule 1 Yes/
No4.3 Is appeal accompanied by the fee of 50 Rs? Sub rule 4 Yes/
No
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Conclusion
Visit to IPCA, laboratories, Ratlam has been pleasant and
knowledgeable experience in term of both theoretical and practical
knowledge. This golden opportunity to have a close view to processes
involved in the effluent treatment plant have enriched my knowledge
regarding environmental hazardous and safety related matters. . I have
gathered brief information about manufacturing processes. Learning
over here was worth attaining any vocational training. This tour also
tackled me with interaction with other departmental employees. It also
taught me to be responsible towards ones environment, rule books have
set of guidelines but how to concern for ones environment was learnt
over here. Managing environment is worth praising. The hygiene and
safety is as per the standards not only pertaining to Indian norm but
global norms.
I hope company shall maintain its standards in futures, and one day
must evolve as leading global pharmaceutical industry.
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