of sgr laboratories pvt. ltd. labs pvt ltd... · 2019-06-27 · dr. y. rama mohan p. praveen kumar...

DRAFT ENVIRONMENTAL IMPACT ASSESSMENT REPORT

& ENVIRONMENTAL MANAGEMENT PLAN

OF

SGR LABORATORIES PVT. LTD.

LOCATED AT

Sy No: 290 & Parts, Dondapadu (V) Chintalapalem (M), Suryapet District, Telangana State.

FOR

PROPOSED BULK DRUGS AND INTERMEDIATES

MANUFACTURING UNIT

Proposal for

ENVIRONMENTAL CLEARANCE Industry falls under 5(f) ‘A’ Category as per the EIA Notification, 2006.

Area: 9.00 Acres

Project Cost: 12 Crores.

Baseline Period – Oct – 2018 to Dec - 2018

Project Proponent

Mr. A. Koti Reddy,

Director,

Plot No.108, SVCIE, IDA,

Jeedimetla, Hyderabad,

Telangana State -500055

Prepared by:

Rightsource Industrial Solutions Pvt. Ltd Plot No: 203, H.No:5-36/203, Prashanthi Nagar, IDA, Kukatpally, Hyderabad – 500072. Ph: 040-23070602, 23075699. 40126589. Email: [email protected].

NABET Accreditation No: NABET/EIA/1821/RA 0100

mailto:[email protected]

UNDERTAKING BY PROJECT

AUTHORITIES

UNDERTAKING BY THE PROJECT AUTHORITIES

This is to undertake that I own the contents (information and data) of the Draft EIA

Report prepared for Green field project of SGR Laboratories Pvt. Ltd. at Survey

No: 290 & Parts, Dondapadu Village, Chinthalapalem Mandal, Suryapet District,

Telangana. I also confirm that I shall be fully accountable for any misleading

information mentioned in this report.

Place: Hyderabad

Date: 26/02/2019

For SGR Laboratories Pvt. Ltd.

Mr. A. Koti Reddy

Director

DISCLOSURE OF CONSULTANTS

ENGAGED

ANNEXURE

Declaration by Experts contributing to the Draft EIA of SGR Laboratories Pvt. Ltd. , Sy No:

290 and parts, Dondapadu (V) Chinthalapalem (M), Suryapet District, Telangana state.

I, hereby, certify that I was a part of the EIA team in the following capacity that developed the

above Draft EIA.

EIA coord inator:

Name: P. S. N. Murthy

Signature: ~ Period of involvement: April 2018 - Till date

Contact information: Rightsource Industrial Solutions Pvt. Ltd.

Plot No: 203, H.No:5-36/203, Prashanthi Nagar, IDA,

Kukatpally, Hyderabad- 500072. Ph: 040-23070602, 23075699.

[email protected] , [email protected]

Functional Area Experts:

s. Functional Name of the Involvement Signature No. areas expertls (period and task-)

Period: April 2018 -Till date Task: Selecting ambient air monitoring sites based on IMD

~ P.S.N. data, Review of the 1 AP Murthy meteorological data, Process

em1ss1ons and AAQ data, suggesting air pollution control measures.

Period: April 2018 -Till date Task: Identification of water

~ P.S.N. monitoring sites, estimating 2 WP Murthy water requirement, Suggesting

Recycling of water, waste water treatment methods & disposal schemes.

Period: April 2018- Till date

~ P.S.N. Task: I nventorization of

3 SHW* Murthy Hazardous waste, Solid wastes, etc. , suggesting treatment options viz., landfill, incineration,

DECLARATION OF ASSOCIATION IN THE EIA

S. Functional Name of the No. areas expert/s

4 SE

5 EB

6 HG

7 GEO

8 AQ

Setti VR Bhaskara

Rao

Dr. K. Bayapureddy

E. V. Naresh Kumar

E. V. Naresh Kumar

P. Praveen Kumar

Involvement (period and task**)

recycling, and stabilization.

Period: April 2018- Till date Task: Generating primary SE data, livestock inventory and impacts, conducted focused group discussions, taken public opinion on the project. Identified villages wise amenities and needs

Period: April 2018- Till date Task: Collected secondary data from forest/ agricultural/ fisheries department, generation of primary flora and fauna data from study area & core area, ground truthing for ecological assessment, development of status report, suggested species for greenbelt development.

Period: Oct 2018- Till date Task: Measurement of ground water levels from the existing wells present in and around project site, observation of surface water bodies, establishing groundwater flow direction and its gradient and evaluation of rainfall data and suggesting suitable depth for secured land fill base, and identification of development of monitoring wells.

Period: Oct 2018 -Till date Task: Observations made towards the Identification of country rock, development of porosity, thickness and extent of weathered formations, area seismicity and evaluation of soil permeability for suggesting suitable civil structures.

Period: April 2018 - Till date Task: Meteorological & Air Pollution dispersion studies, suggesting environmental

Signature

\-~ ~


s. No.

9

10

11

12

S. No.

1

2

Functional areas

NV

LU

RH

sc

Name of the

expert/s

Yarlagadda V. Prasad

Dr. Y. Rama Mohan

P. Praveen Kumar

Dr. K. Bayapureddy

Involvement (period and task**)

Period: April 2017 - Till date Task: Monitoring of noise I vibration levels using instrument, processing and analysis of Data for suggesting suitable noise mitigating measures

Period: October 2018 - Till date Task: Collection of GPS readings from the project site and prepared layout, preparation of TOPO map through SOl 1 :50,000 scale TOPO sheet. Collections of ground through data from the field. Preparation of LU map through Satellite imagery, SOl, Google map & Ground through data.

Period: April 2018 -Till date Task: Identification of Hazards and Hazardous substances from process & warehouse, storage tanks. Risks and consequence analysis using software and lethality damages, DMP and EPP for onsite & offsite were provided

Period: Oct 2018 -Till date Task: Monitoring of soil condition at project site and analysis of baseline data for suggesting suitable soil conservation measures.

Functional Name of the FAAs Involvement Areas Period

AP&AQ Y. Prathyusha April 2018 - Till date

LU G. Sandeep April 2018 - Till date

Signature

Signature

f,-ofh~tAS~

Wf•


Functional Name of the Team Involvement S. No. Signature

Areas Members Period

1 sc G. Raja Reddy April 2018 -Till date ~

2 RH Y. Prathyusha April 2018 - Till date - Ruthrs~

3 WP&SHW* K Aruna Kumari Dec 2018- Till date k' -~

Declaration by the Head of the accredited consultant organization/ authorized person

I, Yarlagadda V. Prasad, hereby, confirm that the above mentioned experts prepared

the EIA of SRR Laboratories at Sy. No. 290 & Parts, Dondapadu (V), Chinthalapalem

(M), Suryapet District, Telangana. I also confirm that the consultant organization shall

be fully accountable for any mis-leading information mentioned in this statement.

Signature:

Name: Yarlagadda V. Prasad

Designation: Managing Director

Name of the EIA consultant organization: Rightsource Industrial Solutions Pvt. Ltd.

NABET Certificate No. & Issue Date: NABET Accreditation No: NABET/EIA/1821/RA 0100

DECLARATION OF ASSOCIATION IN THE EIA •

COPY OF

TERMS OF REFERENCE [TOR]

No.IA-J-11011/14/2019-IA-II(I)

Goverment of India

Minister of Enviroment,Forest and Climate Change

Impact Assessment Division

***

Indira Paryavaran Bhavan,

Vayu Wing,3rd Floor,Aliganj,

Jor Bagh Road,New Delhi-110003

13 Feb 2019

To,

M/s SGR LABORATORIES PVT LTD

Plot No. 108, SVCIE, IDA, Jeedimetla, Hyderabad,

Rangareddi-500055

Telangana

Tel.No.040-23070602; Email:[email protected]

Sir/Madam,

This has reference to the proposal submitted in the Ministry of Environment, Forest

and Climate Change to prescribe the Terms of Reference (TOR) for undertaking detailed EIA

study for the purpose of obtaining Environmental Clearance in accordance with the provisions of

the EIA Notification, 2006. For this purpose, the proponent had submitted online information in the

prescribed format (Form-1 ) along with a Pre-feasibility Report. The details of the proposal are

given below:

1. Proposal No.: IA/TG/IND2/90705/2019

2. Name of the Proposal:

Proposed Bulk Drugs and Drug Intermediates

Manufacturing Unit by SGR Laboratories

Private Limited

3. Category of the Proposal: Industrial Projects - 2

4. Project/Activity applied for: 5(f) Synthetic organic chemicals industry (dyes

& dye intermediates; bulk

5. Date of submission for TOR: 08 Jan 2019

In this regard, under the provisions of the EIA Notification 2006 as amended, the Standard TOR

for the purpose of preparing environment impact assessment report and environment

management plan for obtaining prior environment clearance is prescribed with public consultation

as follows:

STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FOR PROJECTS/ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

5(f):STANDARD TERMS OF REFERENCE FOR CONDUCTINGENVIRONMENT IMPACT ASSESSMENT STUDY FOR SYNTHETICORGANIC CHEMICALS INDUSTRY (DYES & DYEINTERMEDIATES; BULK DRUGS AND INTERMEDIATESEXCLUDING DRUG FORMULATIONS; SYNTHETIC RUBBERS;BASIC ORGANIC CHEMICALS, OTHER SYNTHETIC ORGANICCHEMICALS AND CHEMICAL INTERMEDIATES) ANDINFORMATION TO BE INCLUDED IN EIA/EMP REPORT

A. STANDARD TERMS OF REFERENCE

1) Executive Summary

2) Introduction

i. Details of the EIA Consultant including NABET accreditation

ii. Information about the project proponent

iii. Importance and benefits of the project

3) Project Description

i. Cost of project and time of completion.

ii. Products with capacities for the proposed project.

iii. If expansion project, details of existing products with capacities and whether adequate landis available for expansion, reference of earlier EC if any.

iv. List of raw materials required and their source along with mode of transportation.

v. Other chemicals and materials required with quantities and storage capacities

vi. Details of Emission, effluents, hazardous waste generation and their management.

vii. Requirement of water, power, with source of supply, status of approval, water balance diagram,man-power requirement (regular and contract)

viii. Process description along with major equipments and machineries, process flow sheet(quantative) from raw material to products to be provided

ix. Hazard identification and details of proposed safety systems.

x. Expansion/modernization proposals:

c. Copy of all the Environmental Clearance(s) including Amendments thereto obtained forthe project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of thelatest Monitoring Report of the Regional Office of the Ministry of Environment and Forestsas per circular dated 30th May, 2012 on the status of compliance of conditions stipulatedin all the existing environmental clearances including Amendments shall be provided. In

STANDARD TERMS OF REFERENCE (TOR) FOR EIA/EMP REPORT FORPROJECTS/ACTIVITIES REQUIRING ENVIRONMENT CLEARANCE

addition, status of compliance of Consent to Operate for the ongoing Iexisting operationof the project from SPCB shall be attached with the EIA-EMP report.

d. In case the existing project has not obtained environmental clearance, reasons for nottaking EC under the provisions of the EIA Notification 1994 and/or EIA Notification2006 shall be provided. Copies of Consent to Establish/No Objection Certificate andConsent to Operate (in case of units operating prior to EIA Notification 2006, CTE andCTO of FY 2005-2006) obtained from the SPCB shall be submitted. Further, compliancereport to the conditions of consents from the SPCB shall be submitted.

4) Site Details

i. Location of the project site covering village, Taluka/Tehsil, District and State, Justificationfor selecting the site, whether other sites were considered.

ii. A toposheet of the study area of radius of 10km and site location on 1:50,000/1:25,000 scaleon an A3/A2 sheet. (including all eco-sensitive areas and environmentally sensitive places)

iii. Details w.r.t. option analysis for selection of site

iv. Co-ordinates (lat-long) of all four corners of the site.

v. Google map-Earth downloaded of the project site.

vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plantarea, greenbelt area, utilities etc. If located within an Industrial area/Estate/Complex, layoutof Industrial Area indicating location of unit within the Industrial area/Estate.

vii. Photographs of the proposed and existing (if applicable) plant site. If existing, showphotographs of plantation/greenbelt, in particular.

viii. Landuse break-up of total land of the project site (identified and acquired), government/private - agricultural, forest, wasteland, water bodies, settlements, etc shall be included. (notrequired for industrial area)

ix. A list of major industries with name and type within study area (10km radius) shall beincorporated. Land use details of the study area

x. Geological features and Geo-hydrological status of the study area shall be included.

xi. Details of Drainage of the project upto 5km radius of study area. If the site is within 1 kmradius of any major river, peak and lean season river discharge as well as flood occurrencefrequency based on peak rainfall data of the past 30 years. Details of Flood Level of theproject site and maximum Flood Level of the river shall also be provided. (mega green fieldprojects)

xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition processand expected time of complete possession of the land.

xiii. R&R details in respect of land in line with state Government policy.


5) Forest and wildlife related issues (if applicable):

i. Permission and approval for the use of forest land (forestry clearance), if any, andrecommendations of the State Forest Department. (if applicable)

ii. Landuse map based on High resolution satellite imagery (GPS) of the proposed site delineatingthe forestland (in case of projects involving forest land more than 40 ha)

iii. Status of Application submitted for obtaining the stage I forestry clearance along with lateststatus shall be submitted.

iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere Reserves,Migratory Corridors of Wild Animals, the project proponent shall submit the map dulyauthenticated by Chief Wildlife Warden showing these features vis-à-vis the project locationand the recommendations or comments of the Chief Wildlife Warden-thereon.

v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the StateGovernment for conservation of Schedule I fauna, if any exists in the study area.

vi. Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to theStanding Committee of the National Board for Wildlife.

6) Environmental Status

i. Determination of atmospheric inversion level at the project site and site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and directionand rainfall.

ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and otherparameters relevant to the project shall be collected. The monitoring stations shall be basedCPCB guidelines and take into account the pre-dominant wind direction, population zoneand sensitive receptors including reserved forests.

iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in theNAQQM Notification of Nov. 2009 along with - min., max., average and 98% values foreach of the AAQ parameters from data of all AAQ stations should be provided as an annexureto the EIA Report.

iv. Surface water quality of nearby River (100m upstream and downstream of discharge point)and other surface drains at eight locations as per CPCB/MoEF&CC guidelines.

v. Whether the site falls near to polluted stretch of river identified by the CPCB/MoEF&CC, ifyes give details.

vi. Ground water monitoring at minimum at 8 locations shall be included.

vii. Noise levels monitoring at 8 locations within the study area.

viii. Soil Characteristic as per CPCB guidelines.

ix. Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials,additional traffic due to proposed project, parking arrangement etc.


x. Detailed description of flora and fauna (terrestrial and aquatic) existing in the study areashall be given with special reference to rare, endemic and endangered species. If Schedule-I fauna are found within the study area, a Wildlife Conservation Plan shall be prepared andfurnished.

xi. Socio-economic status of the study area.

7) Impact and Environment Management Plan

i. Assessment of ground level concentration of pollutants from the stack emission based onsite-specific meteorological features. In case the project is located on a hilly terrain, theAQIP Modelling shall be done using inputs of the specific terrain characteristics fordetermining the potential impacts of the project on the AAQ. Cumulative impact of all sourcesof emissions (including transportation) on the AAQ of the area shall be assessed. Details ofthe model used and the input data used for modelling shall also be provided. The air qualitycontours shall be plotted on a location map showing the location of project site, habitationnearby, sensitive receptors, if any.

ii. Water Quality modelling - in case of discharge in water body

iii. Impact of the transport of the raw materials and end products on the surrounding environmenthall be assessed and provided. In this regard, options for transport of raw materials andfinished products and wastes (large quantities) by rail or rail-cum road transport or conveyor-cum-rail transport shall be examined.

iv. A note on treatment of wastewater from different plant operations, extent recycled and reusedfor different purposes shall be included. Complete scheme of effluent treatment. Characteristicsof untreated and treated effluent to meet the prescribed standards of discharge under E(P)Rules.

v. Details of stack emission and action plan for control of emissions to meet standards.

vi. Measures for fugitive emission control

vii. Details of hazardous waste generation and their storage, utilization and management. Copiesof MOU regarding utilization of solid and hazardous waste in cement plant shall also beincluded. EMP shall include the concept of waste-minimization, recycle/reuse/recovertechniques, Energy conservation, and natural resource conservation.

viii. Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A detailedplan of action shall be provided.

ix. Action plan for the green belt development plan in 33 % area i.e. land with not less than1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shallbe included. The green belt shall be around the project boundary and a scheme for greeningof the roads used for the project shall also be incorporated.

x. Action plan for rainwater harvesting measures at plant site shall be submitted to harvestrainwater from the roof tops and storm water drains to recharge the ground water and also to


use for the various activities at the project site to conserve fresh water and reduce the waterrequirement from other sources.

xi. Total capital cost and recurring cost/annum for environmental pollution control measuresshall be included.

xii. Action plan for post-project environmental monitoring shall be submitted.

xiii. Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency ManagementPlan including Risk Assessment and damage control. Disaster management plan should belinked with District Disaster Management Plan.

8) Occupational health

i. Plan and fund allocation to ensure the occupational health & safety of all contract and casualworkers

ii. Details of exposure specific health status evaluation of worker. If the workers' health is beingevaluated by pre designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far& Near vision, colour vision and any other ocular defect) ECG, during pre placement andperiodical examinations give the details of the same. Details regarding last month analyzeddata of above mentioned parameters as per age, sex, duration of exposure and departmentwise.

iii. Details of existing Occupational & Safety Hazards. What are the exposure levels of hazardsand whether they are within Permissible Exposure level (PEL). If these are not within PEL,what measures the company has adopted to keep them within PEL so that health of the workerscan be preserved,

iv. Annual report of heath status of workers with special reference to Occupational Health andSafety.

9) Corporate Environment Policy

i. Does the company have a well laid down Environment Policy approved by its Board ofDirectors? If so, it may be detailed in the EIA report.

ii. Does the Environment Policy prescribe for standard operating process / procedures to bringinto focus any infringement / deviation / violation of the environmental or forest norms /conditions? If so, it may be detailed in the EIA.

iii. What is the hierarchical system or Administrative order of the company to deal with theenvironmental issues and for ensuring compliance with the environmental clearanceconditions? Details of this system may be given.

iv. Does the company have system of reporting of non compliances / violations of environmentalnorms to the Board of Directors of the company and / or shareholders or stakeholders atlarge? This reporting mechanism shall be detailed in the EIA report


10) Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to thelabour force during construction as well as to the casual workers including truck drivers duringoperation phase.

11) Enterprise Social Commitment (ESC)

i. Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the EnterpriseSocial Commitment based on Public Hearing issues and item-wise details along with timebound action plan shall be included. Socio-economic development activities need to beelaborated upon.

12) Any litigation pending against the project and/or any direction/order passed by any Court of Lawagainst the project, if so, details thereof shall also be included. Has the unit received any noticeunder the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and WaterActs? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.

13) 'A tabular chart with index for point wise compliance of above TOR.

B. SPECIFIC TERMS OF REFERENCEFOREIASTUDIES FOR SYNTHETICORGANIC CHEMICALS INDUSTRY (DYES & DYE INTERMEDIATES;BULK DRUGS AND INTERMEDIATES EXCLUDING DRUGFORMULATIONS; SYNTHETIC RUBBERS; BASIC ORGANICCHEMICALS, OTHER SYNTHETIC ORGANIC CHEMICALS ANDCHEMICAL INTERMEDIATES)

1. Detailsonsolvents to be used,measuresfor solventrecovery and for emissions control.

2. Details of process emissions from the proposed unit and its arrangement to control.

3. Ambient air quality data should include VOC, otherprocess-specificpollutants* like NH3*, chlorine*,HCl*, HBr*, H2S*, HF*,etc.,(*-asapplicable)

4. Work zone monitoring arrangements for hazardous chemicals.

5. Detailed effluent treatment scheme including ssegregation of effluent streams for units adopting'Zero' liquid discharge.

6. Action plan for odour control to be submitted.

7. A copy of the Memorandum of Understanding signed with cement manufacturers indicating clearlythat they co-process organic solid/hazardous waste generated.

8. Authorization/Membership for the disposal of liquid effluent in CETP and solid/hazardous waste inTSDF, if any.

9. Action plan for utilization of MEE/dryers salts.

10. Material Safety Data Sheet for all the Chemicals are being used/will be used.

11. Authorization/Membership for the disposal of solid/hazardous waste in TSDF.


12. Details of incinerator if to be installed.

13. Risk assessment for storage and handling of hazardous chemicals/solvents. Action plan for handling& safety system to be incorporated.

14. Arrangements for ensuring health and safety of workers engaged in handling of toxic materials.

***

TOR COMPLIANCE

TOR Compliance SGR Laboratories Pvt. Ltd.

Prepared By Rightsource Industrial Solutions Pvt. Ltd Page I

ToR COMPLIANCE

S. No Standard Terms of Reference Chapters Page Nos

1. Executive Summary Enclosed in Draft EIA Report

2. Introduction

1. Details of the EIA Consultant including NABET

accreditation Enclosed as Enclosure -II

2. Information about the project proponent Chapter - I 2

3. Importance and benefits of the project Chapter - VIII 307

3 Project Description

I. 1. Cost of project and time of completion Chapter - I Chapter - II

1 15-16

II. 2. Products with capacities for the proposed

project. Chapter - II 15

III.

3. If expansion project, details of existing products with capacities and whether adequate land is available for expansion, reference of earlier EC if any.

It is a Greenfield project

IV. 4. List of raw materials required and their source

along with mode of transportation. Chapter - II 112-118

V. 5. Other chemicals and materials required with

quantities and storage capacities. Chapter - VII 252

VI 6. Details of Emission, effluents, hazardous waste

generating and their management Chapter - X 312-325

VII.

7. Requirement of water, power, with source of supply, status of approval, water balance diagram, man-power requirement (regular and contract)

Chapter - II Chapter - VIII

103-104 304

VIII.

8. Process description along with major equipments and machineries, process flow sheet (quantities) from raw material to products to be provided.

Chapter - II 17-99

IX. 9. Hazard identification and details of proposed

safety systems. Chapter - VII 241-251

X.

X. Expansion/modernization proposals a. Copy of all Environmental Clearance (s) including Amendments thereto obtained for the project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of the latest Monitoring report of the Regional Office of the Ministry of Environment and Forests as per circular dated 30th May, 2012 on the status of compliance of conditions stipulated in all the existing environmental clearances including Amendments shall be provided In addition, status of compliance of consent to operate for

It is a Greenfield Project


Prepared By Rightsource Industrial Solutions Pvt. Ltd Page II


the ongoing existing operation of the project from SPCB shall be attached with the EIA-EMP report. d. In case the existing project has not obtained environmental clearance, reasons for not taking EC under the provisions of the EIA Notification 2006 shall be provided. Copies of Consent to Establish /No Objection Certificate and Consent to Operate (in case of units operating prior to EIA Notification 2006, CTE and CTO of FY 2005-2006) obtained from the SPCB shall be submitted. Further, compliance report to the conditions of consents from the SPCB shall be submitted

4

Site Details i. Location of the project site covering village,

Taluka /Tehsil, District and State, Justification for selecting the site, whether other sites were considered.

ii. A toposheet of the study area of radius of 10 KMs and site location on 1:50,000/1:25,000 scale on an A3/A2 sheet. (including all eco-sensitive areas and environmentally sensitive places)

iii. Details w.r.t. option analysis for selection of site

iv. Co-ordinates (lat-long) of all four corners of the site.

v. Google map –Earth downloaded of the project site

vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. If located within an Industrial area/Estate /Complex, layout of Industrial Area indicating location of unit within the Industrial area/Estate.

vii. Photographs of the proposed and existing (if

Chapter - II Chapter - I

Chapter - II

Site is suitable for Industrial

Establishment & no need of

alternative site analysis.

Chapter - II

Chapter - II

Chapter - II

Chapter - II

8 4

13

13

11

14

12


Prepared By Rightsource Industrial Solutions Pvt. Ltd Page III


applicable) plant site. If existing, show photographs of plantation /greenbelt, in particular.

viii. Landuse break up of total land of the project site (identified and acquired), government/ private-agricultural, forest, wasteland, water bodies, settlement, etc shall be included. (not required for industrial area)

ix. A list of major industries with name and type within study area (10KMs radius) shall be incorporated. Land use details of the study area

x. Geological features and Geo-hydrological status of the study area shall be included.

xi. Details of Drainage of the project upto 5km radius of study area. If the site is within 1 km radius of any major river, peak and lean season river discharge as well as flood occurrence frequency based on peak rainfall data of thee past 30 years, Details of Flood Level of the project site and maximum Flood level of the river shall also be provided. (mega green field projects)

xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition process and expected time of complete possession of the land.

xiii. R&R details in respect of land in line with state Government policy.

Chapter - II

Chapter - I

Chapter - III

Proposed land for unit was acquired

by Proponent

The proposed unit is established in

9.0 Acres, so R&R is applicable

9

4

127


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5

Forest and wildlife related issues (if applicable)

i. i. Permission and approval for the use of forest land (forestry clearance), if any, and recommendations of the State Forest Department (if applicable) ii. Landuse map base on High resolution satellite imagery (GPS) of the proposed site delineating the forestland (in case of projects involving forest land more than 40 ha) iii. Status of Application submitted for obtaining the stage I forestry clearance along with latest status shall be submitted. iv. The projects to be located within 10 KMs of the National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit the map duly authenticated by chief wildlife warden showing these features vis-à-vis the project location and the recommendations or comments of the Chief Wildlife Warden –there on. v. Wildlife Conservation plan duly authenticated by the chief wildlife warden of the state government for conservation of schedule 1 fauna, if any exists in the study area. vi. Copy of application submitted for clearance under the wildlife (Protection) Act, 1972, to be standing committee of the national board for wildlife.

The project area is non- forest land. Land use map based on satellite imaginary of the proposed site is presented in chapter - III, Page no: 171-172 Not applicable There are no National parks, Sanctuaries, Biosphere Reserves, Migratory corridors of Wild Animals, within the 10 Km buffer zone Not Applicable Not Applicable

6 Environmental Status

i. i) Determination of atmospheric inversion level at the project site and site-specific micro-

meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall.

Chapter - III

128- 131

https://www.google.co.in/search?rlz=1C1AOHY_enIN718IN718&q=meteorological&spell=1&sa=X&ved=0ahUKEwjw2-_y-NfRAhXKq48KHe0rD1sQvwUIGCgA


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ii) AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and other parameters relevant to the project shall be collected. The monitoring stations shall be based CPCB guidelines and take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests.

ii. iii) Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the NAQQM Notification of Nov.2009 along with –min., max., average and 98% values for each of the AAQ parameters from data of all AAQ stations should be provided as an annexure to the EIA Report.

iii. iv. iv) Surface water quality of nearby River (100m

upstream and downstream of discharge point and other surface drains at eight locations as per CPCB / MoEF&CC guidelines. V) Whether the site falls near to polluted stretch of river identified by the CPCB/ MoEFCC, if yes give details. Vi) Ground water monitoring at minimum at 8 locations shall be included vii) Noise levels monitoring at 8 locations within the study area. Viii) Soil characteristic as per CPCB guidelines. ix) Traffic study of the area, type of vehicles, frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc. x) Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area shall be given with special reference to rare, endemic and endangered species. If Schedule-I fauna are found within the study area, a wildlife conservation plan shall be prepared and furnished.

Chapter - III

Chapter - III

Chapter - III

Not Applicable

Chapter - III

Chapter - III

Chapter - III

Chapter - III

Chapter - III

134-135

137-143

146-147

148-149

154-155

160-162

157-159

173-190


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xi) Socio-economic status of the study area. Chapter - III 190-193

7 Impact and Environment Management Plan

i. i) Assessment of ground level concentration of pollutants from the stack emission based on site –specific meteorological features. In case the project is located on a hilly terrain, the AQIP Modeling shall be done using inputs of the specific terrain characteristics for determining the potential impacts of the project on the AAQ. Cumulative impact of all sources of emissions (including transportation) on the AAQ of the area shall be assessed. Details of the model used and the input data used for modeling shall also be provided. The air quality contours shall be plotted on a location map showing the location of project site, habitation nearby, sensitive receptors, if any.

ii. iii. ii) Water Quality modeling –in case of discharge

in water body iii) Impact of the transport of the raw materials and end products on the surrounding environment hall be assessed and provided. In this regard, options for transport of raw materials and finished products and wastes (large quantities) by rail or rail-cum road transport or conveyor- cum –rail transport shall be examined. iv) A note on treatment of wastewater from different plant operations, extent recycled and reused for different purposes shall be included. Complete scheme of effluent treatment, Characteristics of untreated and treated effluent to meet the prescribed standards of discharge under E (P) Rules. v) Details of stack emission and action plan for control of emissions to meet standards VI) Measures for fugitive emission control

Chapter - IV

The proposed unit will employ ZLD

system

Chapter - X

Chapter - X

Chapter - X

Chapter - X

326-329

313

314-323

312

334-337


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VII) Details of hazardous waste generation and their storage, utilization and management. Copies of MOU regarding utilization of solid and hazardous waste in cement plant shall also be included. EMP shall include the concept of waste – minimization, recycle/reuse/ recover techniques, Energy conservation, and natural resource conservation. VIII) Proper utilization of fly ash shall be ensured as per fly ash notification, 2009. A detailed plan of action shall be provided. IX) Acton plan for the green belt development plan in 33% area i.e. land with not less than 1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shall be included. The green belt shall be around the project boundary and a scheme for greening of the roads used for the project shall also be incorporated. X) Action plan for rainwater harvesting measures at plant site shall be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources. XI) Total capital cost and recurring cost /annum for environmental pollution control measures shall be included. XII) Action plan for post –project environment monitoring shall be submitted. XIII) Onsite and offsite Disaster (natural and Man –made) Preparedness and Emergency Management Plan including Risk Assessment and damage control. Disaster management plan should be linked with District Disaster Management Plan.

Chapter - X

Chapter - X Chapter - IV

Chapter - X

Chapter - X

Chapter - X

Chapter - VI Chapter - X

Chapter - VII

339

339 218

329-330

340-341

342

230-232 331-332

287-303

8 Occupational health

i. Plan and fund allocation to ensure the Chapter - VII 278-281


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occupational health & safety of all contract and casual workers

ii. Details of exposure specific health status evaluation of workers’ health is being evaluated by pre designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far & Near vision, colour vision and any other ocular defect) EGG, during pre placement and periodical examinations give the details of the same details regarding last month analyzed data of above mentioned parameters as per age, sex, duration of exposure and department wise. Details of existing Occupational & safety Hazards. What are the exposure levels of hazards and whether they are within permissible Exposure level (PEL) If these are not within PEL, what measures the company has adopted to keep them within PEL so that health of the workers. Can be preserved, Annual report of heath status of workers with special reference to Occupational Health and safety.

9

Corporate Environment Policy i. Does the company have a well laid down Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report. ii. Does the Environment Policy prescribe for standard operation process / procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms/ conditions? If so, it may be detailed in the EIA. iii. What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance with the environmental clearance conditions? Details of this system may be given iv. Does the company have system of reporting of non compliance /violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism shall be detailed in the EIA report.

Chapter -VI - - -

226-227 - - -


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10

Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to the labour force during construction as well as to the casual workers including truck drivers during operation phase.

The proposed unit will provide all the facilities for construction labour during construction phase and as well as the casual workers including truck drivers during operation phase

11

Enterprise Social Commitment(ESC) 1. Adequate funds (at least 2.5% of the project

cost) shall be earmarked towards the Enterprise social commitment based on public hearing issues and item –wise details along with time bound action plan shall be included socio-economic development activities need to be elaborated upon.

Chapter - VIII The fund allocated for Enterprise Social Commitment will be utilized as suggested during Public Hearing

305 - 306

12

Any litigation pending against the project and / or any direction/ order passed by any Court or law against the project, if so, details thereof shall also be included. Has the unit received any notice under the section 5 of environment (protection) Act 1986 or relevant sections of air and water acts? If so, details thereof and compliance /ATR to the notice (s) and present status of the case.

No Litigations against proposed project

13 A tabular chart with index for point wise compliance of above TOR.

Enclosed along with EIA & EMP Report

A Specific ToR

1 Details on solvents to be used, measures for solvent recovery and for emissions control.

Chapter - X 334-337

2 Details of process emissions from the proposed unit and its arrangement to control

Chapter - X 333-334

3 Ambient air quality data should include VOC, etc.,

Chapter - III 143

4 Work zone monitoring arrangements for hazardous chemicals

Chapter - VII 258-260

5 Detailed effluent treatment scheme including segregation of effluent streams for units adopting zero liquid discharge

NA NA

6 Action plan for odour control to be submitted; - -

7

A copy of the Memorandum of Understanding signed with cement manufactures indicating clearly that they co-process organic solid/hazardous waste generated.

Yet to make MOU with Cement Industries as it is a Greenfield Project

8 Authorization / Membership for the disposal of liquid effluent I CETP and solid/ hazardous waste in TSDF, If any.

Yet to take Membership of TSDS as it is a Proposed Project


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9 Action plan for utilization of MEE/dryers salts. Chapter -X 465

10 Material safety data sheet for all the chemicals are being used/ will be used.

MSDS for all the chemicals will be used and kept in plant for reference.

11 Authorization/ Membership for the disposal of solid/hazardous waste in TSDF are being used /will be used

Yet to take Membership of TSDF as it is a Proposed Project

12 Details of incinerator if to be installed No proposal for installation of Incinerator

13 Risk assessment for storage and hazardous chemicals/solvents, Action plan for handling & safety system to be incorporated.


14 Arrangements for ensuring health and safety of workers engaged in handling of toxic materials.


LIST OF CONTENTS

[INDEX]

Index of Draft EIA Report SGR Laboratories Pvt. Ltd

Prepared By Rightsource Industrial Solutions Pvt. Ltd

LIST OF CONTENTS

CHAPTER - I INTRODUCTION

S. No Description Page No

1.1 Purpose of the Project 1

1.2 Identification of project & Project proponent 1

1.2.1 Identification of Project 1

1.2.2 About the Promoters 1

1.3 Objective and Scope of the Study 2

1.4 Brief Description of the Project 2

1.4.1 Nature of the Project 2

1.4.2 Size of the Project 3

1.4.3 Location of the Project 3

1.4.4 Project and its Importance to the Country & Region.

5

1.5 Scope of Study. 5

1.5.1 Environmental Impact Assessment 5

1.5.2 Socio-Economic Assessment 5

1.5.3 Regulatory Framework 6

1.5.4 Regulatory Scoping 6

1.6 Legal Policy and Institutional Frameworks 6-7

CHA PTER - II PROJECT DESCRIPTION


2.1 Type of the project 8

2.2 Need For The Project 8

2.3 Location 8

2.4 Size and Magnitude of Operation 15

2.5 Proposed schedule for approval and implementation 15-16

2.6 Technology and process description 16

2.6.1 Manufacturing process of the Products 17-99

2.7 Pollution Load 99

2.8 Details of Process Emissions and its mitigation measures

101

2.9 Proposed Water Consumption Details 103

2.10 Expected Waste Water Generation Details 104

2.11 Waste Water Characteristics 106

2.12 Hazardous & Solid Waste Generation Details 106-107

2.13 Power(Energy) requirement 107

2.14 Utilities 107

2.15 Proposed Boilers & DG sets 108

2.16 Details Of Proposed Solvents Input, Recovery & Loss 109

2.17 List Of The Raw Materials Product Wise 112-118

2.18 Environmental aspects, impacts and mitigation measures of proposed industry

118-120

2.19 Assessment of new & untested technology for risk of 121



technological failure

CHAPTER - III DESCRIPTION OF THE ENVIRONMENT


3.0 Introduction 122

3.1 Study Area 122

3.1.2 Study Period 122

3.2 Geological & Hydro geological Environment 122-123

3.2.1 Geomorphology and soil types 123

3.2.2 Geology 124

3.2.3 Hydrogeology 124

3.2.4 Ground water Conditions 124

3.2.5 Drainage Pattern of Study Area 125

3.2.6 Drainage Map 126

3.3 Micrometeorology And Climate 128-129

3.4 Air Environment 133

3.4.1 National Ambient Air Quality Standards (NAAQS) 136

3.4.2 Ambient Air Quality Data (AAQ) 142-143

3.5 Water Environment 145

3.5.1 Methodology For Water Quality Monitoring 145

3.6 Noise Environment 153

3.6.1 Noise Monitoring Stations 153-154

3.6.2 Traffic Study 157

3.7 Soil Environment 160

3.8 Land Use Pattern 164

3.8.1 Data Used 164

3.8.2 Land use / Land Cover Map 165

3.8.2.1 Basic concepts of land use 166

3.8.2.2 Methodology for land use / land cover mapping 166-168

3.9 Ecological Environment 173

3.9.1 Detailed Description of Flora and Fauna 173

3.9.2 Vegetation and Flora of the study area 176

3.9.3 Terrestrial fauna of the project area and the study area

182

3.9.3.1 Methodology for Mammals study 182-183

3.9.3.2 Methodology for Herpeto-fauna 183

3.9.3.3 Methodology for Birds in Study Area 183

3.9.4 Aquatic flora and fauna 186

3.9.5 RET and Schedule I Fauna 189-190

3.10 Socio Economic Study 190

3.10.1 Methodology Adopted for the Study 190

3.10.2 Distribution of Population in the study area 190

3.10.3 Literacy & Illiteracy Rate 191-192

3.10.4 Occupational Structure 192-193

3.10.5 Civic Amenities Available In The Study Area 194-195

3.10.6 Corporate Social Responsibility of the Project Proponent

195



CHAPTER - IV ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES



4.2 Investigated Environmental Impacts Due To Proposed Project

196-197

4.3 Construction Phase 197

4.3.1 Impact on Land Use 197

4.3.2 Impact on Land / Soil Environment 197

4.3.3 Impact on Topography 197-198

4.3.4 Impact on Air Quality 198

4.3.5 Impact on Water Environment 198

4.3.6 Impact on Noise Levels 199

4.3.7 Impact on Ecology 199

4.3.8 Impact on Socio-Economic Environment 199-200

4.4 Mitigative measures of impacts during construction phase

201

4.5 Prediction of Impacts During Operational Phase 203

4.6 Air Environment 204

4.6.1 Source of Air Pollution 204-205

4.6.2 Prediction of Impacts on Air Environment 206-208

4.7 Water Environment 214-216

4.8 Noise Environment 216

4.9 Land/Soil Environment 216-218

4.10 Impact of Solid Waste 218

4.11 Impacts on Ecology 219-220

4.12 Impacts on Socio- Economy 220-221

4.13 Impacts on Hydrology and Geology 221

CHAPTER - V ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE)


5.0 Analysis Of Alternatives 222

5.1 Site Selection Criteria 222-223

5.2 Selection Of Process Technology 223-224

CHAPTER - VI ENVIRONMENTAL MONITORING PROGRAM



6.2 Environmental Management System 225-226

6.3 Environmental Management Cell Responsibilities 226-227

6.4 Environmental Monitoring and Reporting Procedure 228

6.4.1 Objectives of Monitoring 228

6.4.2 Monitoring Schedule for Construction and Operation Phases.

229-230

6.5 Location of Monitoring Stations 232-233



6.6 Monitoring and Data Analysis 233

6.6.1 Air Quality Monitoring and Data Analysis 233-234

6.6.2 Water and Waste Water Quality Monitoring and Data Analysis.

234-235

6.6.3 Noise Levels 235

6.6.4 Soil Quality 235

6.7 Reporting Schedule of the Monitoring Data 235

6.8 Environmental Laboratory 235

6.8.1 Air Quality and Meteorology 236

6.9 Occupational Safety and Health aspects 236

CHAPTER -VII ADDITIONAL STUDIES, RISK ASSESSMENT & DISASTER MANAGEMENT REPORT


7.1. Additional Studies 237

7.1.1 Scope of this Study 237

7.1.2 Methodology 237

7.2 Introduction to Risk Assessment 238

7.2.1 Objectives of Risk Assessment 238

7.2.2 Identification of Hazards 239-240

7.3 Solvents/Chemicals 252

7.4 Potential Hazards of solvents and chemicals 253-258

7.5 Safe practices [handling, storage, transportation and unloading of chemicals]

258

7.5.1 Measures to avoid Evaporation 258

7.5.2 Safety Systems 258-259

7.5.3 Transportation /unloading 259

7.5.4 Spill Control 260

7.5.5 Effect and Consequence Analysis 260

7.6 Inventory 260-261

7.7 Loss of Containment 261-263

7.8 Damage Criteria 263-266

7.9 Damages to human life due to heat radiation 266-267

7.10 Maximum credible loss accident scenarios 267-268

7.11 Risk Analysis 268

7.12 Risk Modeling Scenarios 268-278

7.13 Occupational Health 278-280

7.13.1 Sampling Devices 280-281

7.14 Chemical exposure limits & emp for the occupational safety & health hazards

282-284

7.15 Treatment of workers affected by accidental spillage of chemicals

284-286

7.16 Communication System 286

7.17 Safety Inspections 286

7.18 Predictive and preventive maintenance 286-287

7.19 Onsite emergency plan 287

7.20 Structure of emergency management system



CHAPTER - VIII PROJECT BENEFITS


8.1 Employment Potential 304

8.2 Corporate Social Responsibility (CSR) & CER 304

8.3 Direct revenue earning to the National and State exchequer

307

8.4 Improvements in the Physical Infrastructure 307

8.5 Improvements in the Social Infrastructure 307

8.6 Other Tangible Benefits 307

7.21 Emergency Management system-Roles & Responsibilities

288

7.21.1 Site Main Controller (SMC) 288-289

7.22 Incident Controller/Deputy Incident Controller 289-290

7.23 Key Personnel’s 290

7.24 Essential workers 290-291

7.25 Other Elements of DMP 291

7.26.1 Assembly Point 291-292

7.26.2 Emergency Control Center 292

7.26.3 Fire Services 292-293

7.26.4 Medical Services 293

7.26.5 Security Services 294

7.26.6 Mutual Aid 294

7.27 Emergency Response 295

7.28 Emergency Capabilities 295

7.29 Emergency Handling Procedures 295-297

7.30 Mitigation of Environmental Impact during Fire Emergency

297

7.30.1 Raising the Alarm 298

7.31 Declaring Major Emergency 298

7.32 Transport and evacuation arrangements 298

7.33 Plant Operations 299

7.34 Telephone Messages 299

7.35 Mock Drill 299-300

7.36 Offsite emergency plan 300-302

7.37 Role of the factory management 302

7.37.1 Role of Local Authority 302

7.37.2 Role of Fire Authority 302

7.37.3 Role of Police 302

7.37.4 Role of Health Authorities 302

7.37.5 Role of the Mutual aid agencies 303

7.37.6 Role of the Factory Inspectorate 303



CHAPTER - IX ENVIRONMENTAL COST BENEFIT ANALYSIS


9.1 Cost benefit analysis 308

CHAPTER - X ENVIRONMENTAL MANAGEMENT PLAN



10.2 Pre-Project Environmental Management Plan 311

10.2.1 Site Preparation 311

10.2.2 Sanitation 311

10.2.3 Noise 311

10.2.4 Construction Equipment And Waste 311

10.2.5 Site Security 311

10.3 Environmental Management During Operation 311

10.3.1 Air Quality 311

10.3.1.1 Air Pollution Control / Management 312

A Stack Design 312

B Fugitive Emission from Solvents 312

C Storage and Transportation of Raw Materials 313

10.3.2 Noise Pollution 313

10.3.3 Water Quality 313-315

10.3.3.1 Details of ZLD system 319

10.3.3.2 The technical details of the systems are as follows 320

10.3.3.3 MEE plant configuration 320

10.3.3.4 Process description (Part - A) 320

10.3.3.5 Process description (Part - B) 321-322

10.3.3.6 Process description (Part - C) 322

10.4 Hazardous/ Solid Waste Management 324-325

10.5 EB [Ecology & Biodiversity 325

10.6 SE [Socio-Economic Aspects 325-326

10.7 HG [Hydrogeology, Ground Water & Water Conservation] 326

10.8 GEO [Geology] 327

10.9 SC [Soil Conservation] 327

10.10 RH [Risk & Hazards Management] 328

10.11 Greenbelt Development 328

10.11.1 Objective 328

10.11.2 Action Plan 329

10.12 Post Project Monitoring 330-331

10.12.1 Air Pollution Monitoring 331

10.12.2 Waste Water Monitoring 331

10.12.3 Ground Water Monitoring 331

10.12.4 Hazardous / Solid Waste Monitoring 331-332

10.13 Management of Public Interests 332

10.13.1 Objective 332

10.13.2 Preference To Local Population 333

10.13.3 Health Camps 333



10.13.4 Public Amenities 333

10.13.5 Public Relations 333

10.14 Water Requirement 333

10.15 Process Emission Control System 333

10.16 Fugitive Emissions 334

10.17 Solvent Management Plan 334-337

10.18 Emissions – Utilities 337

10.19 Wastewater Loads 338

10.20 Stage wise Effluent Characteristics 339

10.21 Hazardous & Solid Waste details 339

10.22 Proposed Roof Water Harvesting 340-341

10.23 Investment 342

10.23.1 Budget allocation 342

10.24 Mitigation Plan 342-343

10.25 Socio-Economic development activities 344

10.26 Waste Minimization / Resource Conservation 5 r concept (Recycle / Refuse / Reduce / Reuse / Reform) 344-345

10.27 Conclusion 345-346

CHAPTER - XI SUMMARY & CONCLUSION (THIS WILL CONSTITUETE THE SUMMARY OF THE EIA REPORT)


11.1 Salient features of the project 347

11.2 Conclusions 348

LIST OF TABLES

CHAPTER - I INTRODUCTION

Table No Description Page No

1.1 Proposed Products and Quantities 3

1.2 Proposed By-Products and Quantities 3

1.3 Project location and Compliance of site 4

1.4 Applicability of legal policies to the project 6-7

CHAPTER - II PROJECT DESCRIPTION


2.1 Land use details 9

2.2 List of proposed products and Capacities 15

2.3 List of proposed By-Products and Capacities 15

2.4 Consolidated Pollution Load Of All Products In Per Day Quantities

100

2.5 Process Emission details and Its Mitigation measures

101

2.6 Process Emission Details Product wise 102



2.7 Proposed water consumption details 103

2.8 Proposed water consumption in process product wise

103

2.9 Expected Effluent Generation details 104

2.10 Expected HTDS & LTDS effluent details 104

2.11 Expected Waste water generation in Kg per day Product wise

105

2.12 Expected Hazardous/Solid Waste Generation, Disposal Details

106

2.13 Solid waste generation per day Product wise 107

2.14 Details Of Utilities 107-108

2.15 Emission characteristic details of proposed Boiler 108

2.16 Stack Emission details of proposed DG Set 108

2.17 Details Of Proposed Solvent Input, Recovery & Loss [Product Wise]

109-111



3.1 Showing drainage density based criteria by smith and strahler

126

3.2 Showing drainage density based criteria proposed by Long Bein

126

3.3 Showing Drainage Density Based Criteria Proposed by Horton

126

3.4 Frequency distribution wind directions and wind speed 130

3.5 Comparison of Primary Data (PROJECT SITE) with Secondary Data (IMD DATA)

132

3.6 IMD Data for Nandigama 132

3.7 Ambient air quality sampling locations 134

3.8 National ambient air quality standards 136-137

3.9 Ambient air quality results for PM10 137

3.10 Ambient air quality results for PM2.5 138

3.11 Ambient air quality results for SO2 138

3.12 Ambient air quality results for NOx 139

3.13 Ambient air quality results for CO 140

3.14 Ambient air quality results for NH3 140

3.15 The maximum ,minimum & 98th percentile values for all the sampling locations

144

3.16 Ground water and Surface sampling locations 146

3.17 Ground water quality in the study area 148-149

3.18 Surface water quality the study area 150-151

3.19 Noise monitoring locations 154

3.20 Ambient noise levels within study area 156

3.21 Traffic Study 158-159

3.22 Soil sampling locations 160

3.23 Soil sampling analysis results 162

3.24 Standard Soil Classification 163-164

3.25 Showing the Details of Sources & the Maps Prepared 164



3.26 Showing the Topographic Maps 164

3.27 Satellite Data of National Remote Sensing Center 165

3.28 Land Use / Land Cover Statistics of the Study Area 170

3.29 Ecological Sensitivity details of the project site and its buffer zone of 10 KM Radius

174

3.30 List of plants found in the project area 175-176

3.31 List of Trees, shrubs and perennial climbers Found the study area.

177-180

3.32 Herbaceous species found the Study Area 180-181

3.33 List of vertebrates other than birds found in and around the project site

183-184

3.34 List of Birds either spotted or reported from the areas in and around the project site

184-185

3.35 Aquatic and semi aquatic macrophytes found along the banks and in the shallow waters of Krishna River, Palleru River and Pulichintala reservoir.

186-187

3.36 List of Fishes reported from Krishna River, Palleru River and Pulichintala Reservoir located in the buffer zone of the project site.

187-189

3.37 Population Distribution 190-191

3.38 Distribution of Literacy Rate and Illiteracy Rate in the Study Area

192

3.39 Occupational Structure in Study Area 193

CHAPTER - IV ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES


4.1 Summary – Identification Of Impacts During Construction Phase

200

4.2 Mitigation Measures During Construction Phase 201-203

4.3 Emission Details from Proposed Boiler Stack 204

4.4 Emission Details from DG Set Stack 205

4.5 Predicted 24-Hourly Short Term Incremental Concentrations

208

4.6 Resultant Concentrations Due to Incremental GLC's 208

4.7 Process Emission details and mitigation measures 212

4.8 Hazardous & Solid Waste Disposal Details 219

CHAPTER - V ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE)


5.1 Site Description 222-223





6.1 Post Project Environmental Monitoring schedule details

230

6.2 Environmental Monitoring Plan during Operation Phase

230-232

6.3 Details of Post Project Monitoring Locations 233

CHAPTER -VII ADDITIONAL STUDIES, RISK ASSESSMENT & DISASTER MANAGEMENT REPORT


7.1 Area Wise Identified Hazards, Precautions proposed With Mitigation Measures.

241-251

7.2 Solvent/ Chemicals 252

7.3 Severity Categories and Criteria 263

7.4 Heat flux Intensity and exposure time-Damage criteria for people

266

7.5 Damage due to overpressures 267

7.6 Chemical exposure limits 282



10.1 List of Plants identified for Greenbelt 330

10.2 The details of the Monitoring Program 331-332

10.3 Proposed Water consumption details 333

10.4 Characteristics Details of proposed Boilers 337

10.5 Stack Emission Details of proposed DG set 338

10.6 Effluent generation details 338

10.7 HTDs & LTDs effluent details 338

10.8 Hazardous / Solid waste generation, disposal Details 339

10.9 Available rain water (annual)for Harvesting 341

10.10 Proposed Budget for Environmental Management plan 342

LIST OF FIGURES

CHAPTER - II PROJECT DISCRIPTION

Figure No Description Page No

2.1 Location map 10

2.2 Google Earth Map Showing Project Site 11

2.3 Latest photographs of Proposed site 12

2.4 Topomap showing 10km radius 13

2.5 Site plan details 14





3.1 Showing Drainage Map Of The Project Study Area

127

3.2 Windrose Diagram Period: March 2018 – May 2018

131

3.3 Windrose Diagram of Secondary Data 131

3.4 Ambient Air Quality Sampling Locations Map 135

3.5 Ambient Air Quality Results For PM10 137

3.6 Ambient Air Quality Results For PM2.5 138

3.7 Ambient Air Quality Results For SO2 139

3.8 Ambient Air Quality Results For NOx 139

3.9 Ambient Air Quality Results For CO 140

3.10 Ambient Air Quality Results For NH3 141

3.11 Ground & Surface water sampling Locations Map 147

3.12 Noise Sampling Locations Map 155

3.13 Soil Sampling Locations Map 161

3.14 Pie Diagram showing Land Use in the Study Area 170

3.15 Satellite Imagery of the Study Area 171

3.16 Land Use / Land Cover Map Of The Study Area 172

3.17 Diagram Showing Total Population Distribution in the Study Area

191

3.18 The Diagram Showing Literates and Illiterates in Study Area

192

3.19 The Diagram Showing Occupational Structure in Study Area

193

CHAPTER - IV ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION

MEASURES


4.1 Short term 24 hourly incremental GLCs of SPM 209

4.2 Short term 24 hourly incremental GLCs of SO2 210

4.3 Short term 24 hourly incremental GLCs of NOx 211



6.1 Organisational Structure of Environment Health & Safety

228



10.1 Flow chart of EMP 310

10.2 Schematic diagram of Proposed waste water treatment – ZLD System

316

10.3 Flow chart for effluent treatment HTDS 317



10.4 Flow chart for effluent treatment LTDS 318

10.5 Flow chart for effluent treatment 319

10.6 Schematic diagram of MEE system 323

10.7 Schematic diagram Emissions Control Scrubbing System

334

10.8 Roof water harvesting Structure 341

10.9 5 R concept 345

LIST OF ENCLOSURES

S. No Description Enclosure No

1 Land Document Enclosure – 1

2 Land Conversion Document Enclosure – 2

3 NABET Accreditation Details Enclosure – 3

EXECUTIVE SUMMARY OF

EIA REPORT

EXECUTIVE SUMMARY

OF

DRAFT EIA REPORT

OF

SGR LABORATORIES PVT. LTD.

For

Proposed Bulk Drugs & Intermediates

Manufacturing Unit

AT

Sy No: 290 & Parts, Dondapadu (V), Chinthalapalem (M),

Suryapet District, Telangana state.

PREPARED BY

Rightsource Industrial Solutions Pvt. Ltd

Plot No: 203, H.No:5-36/203, Prashanthi Nagar,

IDA, Kukatpally, Hyderabad – 500072.

Ph: 040-65873137, 23070602, 23075699, 40126589.

Fax: 040-23070602. Mail: [email protected]

NABET Accreditation No. NABET/EIA/1518/SA 038

mailto:[email protected]

Executive Summary of Draft EIA Report SGR Laboratories Pvt. Ltd.

Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 1

1. INTRODUCTION

SGR Laboratories Pvt. Ltd. proposed to establish a Bulk Drugs & Intermediates

manufacturing unit at Sy No: 290 & Parts, Dondapadu (V), Chinthalapalem (M),

Suryapet District, Telangana.

The proposed project cost is about Rs. 12 Crores, which includes construction of the

buildings, equipment, machinery and greenbelt development.

On 17th March, 2018 ToR application was submitted, mentioning the Sy.No. 299 and

its parts instead of Sy.No. 290 and its parts and Standard ToR were granted by

MoEF & CC on 19th April, 2018. Based on granted ToR we have carried out the

baseline monitoring during the period of October to December– 2018.

Due to change in Survey no., on 05th Jan, 2019 we have applied Fresh ToR

application as suggested by MoEF&CC, mentioning the Sy. No. 290 and its parts

and also communicated for utilizing the collected baseline data during the period

from October to December – 2018.

The project proposal was accepted by MoEF&CC and issued Standard Terms of

Reference vide F. No: IA-J-11011/14/2019-IA II (I) Dated on 13th Feb 2019, to

carryout EIA Study.

1.1. PROJECT DESCRIPTION

The salient features of the unit are furnished below.

TABLE 1: SALIENT FEATURES OF THE PROJECT

Project location Details

Latitude & Longitude Latitude: 16° 49' 33.67" N Longitude: 80° 2' 53.39" E

Climatic Conditions

Annual Max Temp is 44.5 0C Annual Min Temp is 12.7 0C Normal Annual Rainfall is 982 mm (Source: IMD Climatalogical Normals, Nandigama 1981 - 2010)

Land acquired for the plant 9.0 Acres (36414 Sq. m)

Nature of Land Patta Land

Nearest Habitation Dondapadu Village - 1.20 km (WSW)

Nearest Town Jaggayyapet – 8.0 km (NE)

National Highway

National Highway No. 9 – 16 km (ENE) (Hyderabad – Vijayawa da Road)



2.0 PROCESS DESCRIPTION

The manufacturing process of Bulk Drugs & Intermediates consists of chemical

synthesis extending to stages of processing involving different type of chemical

reactions. Total production capacity of proposal will be 81 TPM. (Given in Table -2).

The unit will take adequate control measures for storage and handling of Raw

materials with in factory premises.

TABLE 2: PROPOSED PRODUCTS AND QUANTITIES

S. No Name of the Product Quantity in Kg/Month

CAS Number Therapeutic

Category

1 Atorvastatin Calcium 10000 134523-03-8 Antihyperlipidemic

2 Dapoxetine Hydrochloride 4000 129938-20-1 Premature ejaculation

3 D-penicillamine 5000 52-67-5 Antibiotic

Railway station Airport

Motumari Railway Station – 33 km (ENE) Vijayawada Airport – 87 km (ESE)

Interstate Boundary Telangana – Andhra Pradesh Interstate Boundary – 400 meters (NE)

Major Industries near the plant site

1. Zuari cement 2. Sitapuram Power Plant 3. KCP Cement 4. Anjani Portland Cement Limited 5. Ra Chem Pharma Limited 6. Sri Durga Industries 7. Ultratech Balaji Cement works 8. Ultratech Cement Limited 9. Jaypee Balaji Cement Plant

National Parks None within 10 Km radius

Wild life sanctuary None within 10 Km radius

Historical Places Vedadri Lakshmi Narasimha Swamy temple – 8.0 km (E)

Water Bodies within 10 km radius

Krishna River – 2.5 km (ESE) Palleru River – 5.5 km (E) Pulichintala Dam – 5.9 km (S) Water body near Jaggayyapet – 8.3 km (NE) Water body near Ramapuram – 8.0 km (WNW)

Reserve Forest within 10 km radius

Budavada R.F- 2.8 km (N) Balusupadu R.F – 6.0 km (N) Jaggayyapeta Extension R.F – 5.8 km (E) Kuntimadi R.F- 5.2 km (ESE) Ginjupalle R.F- 6.4 km (SE) Venkatayapalem Extension R.F- 6.0km (SE) Venkatayapalem R.F- 5.8 km (SSE) Nemalipuri R.F – 7.6 km (SSW) Chintapalem R.F – 7.6 km(SSW)



4 Duloxetine Hydrochloride 5000 136464-34-9 Anti depressant

5 Lansoprazole 10000 103577-45-3 Anti ulcer

6 Lopinavir 5000 192725-17-0 Anti viral

7 Moxifloxacin hydrochloride 2000 186826-86-8 Anti bacterial

8 Nebivolol 5000 152520-56-4 Anti hypertensive

9 Ritonavir 5000 155213-67-5 Anti viral

10 Sildenafil citrate 15000 171599-83-0 Erective dysfunction

11 Valsartan 15000 137862-53-4 Anti hypertensive

Total 81000

Table 1.2: Proposed By-Products and Quantities

S. No Name of the Product Name of the By-Product Quantity

in Kg/Day

1 Dapoxetine Hydrochloride Isomer for product Recovery 138.67

2 D-penicillamine 2-Phenyl-N-(2-Phenylimino-ethyl)-acetamide

313.57

3 Duloxetine Hydrochloride Isomer for product Recovery 98.75

Mandelic acid 80.79

2.1 RESOURCE REQUIREMENT & INFRASTRUCTURE FACILITIES

A) Land Use Details:

The proposed unit is in an existing area of 9.0 Acres (36414 Sq. m), the usage

details are given Table 3.

TABLE 3: PROPOSED LAND USE DETAILS

S. No. DESCRIPTION AREA IN Sq. m AREA IN Acres AREA IN %

1 Total Built up Area 8998 2.22 24.71

2 Green Belt Area 13660 3.37 37.51

3 Roads Area 8925 2.21 24.51

4 Open Area 4831 1.20 13.27

TOTAL 36414 9.00 100.00

37.51 % of Land is allotted For Green Belt Development



B) Proposed Water Consumption Details

TABLE- 4: PROPOSED WATER CONSUMPTION DETAILS

S. No Purpose Water

input KLD

1 Process 25.13

2 Washings 5.00

3 Boiler make up 30.00

4 Cooling towers make up 63.00

5 Scrubbing system 3.00

6 Domestic 5.00

7 Gardening 3.00

Total 134.13

The fresh water of 90.63 KLD will be met from Ground Water source.

Recovered water 43.50 KLD from ZLD system is reused.

C) Energy Requirement

Power requirement of proposed project will be made available through Telangana

State Power Distribution Company Limited [TSPDCL]. The power requirement of

project will be 2000 KVA.

D) Utilities:

For generation of Steam, the industry proposed to install 2 TPH & 3 TPH coal fired

boilers. The coal requirement will be met from local authorized sources.

The unit is proposing a 500 KVA DG set, for usage during the power failures.

The emission details are presented in Table 6 & 7

TABLE 5: DETAILS OF UTILITIES

S. No

Description Capacity

1 Coal fired boilers 2 TPH & 3 TPH

3 D. G. Set 1 x 500 KVA

4 Cooling Towers 3 x 200 TR

& 1 x 300 TR

5 Electricity supply from TSPDCL

2000 KVA

Fuel Consumption

6 Coal 15.5 TPD

7 Diesel 80 Liters/Day



TABLE 6: EMISSION CHARACTERISTIC DETAILS OF PROPOSED BOILER

Particulars Units 2.0 TPH Coal fired

Boiler 3.0 TPH Coal fired

Boiler

Type of Fuel -- Indian Coal with CV of 4000 kcal/kg to

5000 kcal/kg

Indian Coal with CV of 4000 kcal/kg to

5000 kcal/kg

Coal Consumption TPD 8.00 7.50

Ash Content % 35 35

Sulphur Content % 0.4 0.4

No. of Stacks No 1 1

Height of stack M 30 30

Diameter of Stack M 0.40 0.50

Temperature of Flue Gas oC 175 175

Velocity of Flue Gas m/s 12 14

Particulate gm/sec 0.16 0.15

Sulphur dioxide emission gm/sec 0.74 0.69

Oxides of Nitrogen emission gm/sec 2.43 2.28

TABLE 7: STACK EMISSION DETAILS OF PROPOSED DG SET

Capacity In KVA

Emission of SPM in mg/Nm3

Emission Of SO2 in mg/Nm3

Emission of NOx In mg/Nm3

Stack dia. In m

Flue Gas Temp. in

OC

Stack Height in (m)

Flue gas Velocity In m/sec.

500 KVA 60 85 110 0.2 300 10 14

E) Pollution Control Equipment:

i) Cyclone separator: The denser particles which are carried away by boiler flue

gases will get separated in the cyclone separator and collected in the bottom of the

cyclone separator at a definite interval.

ii) Bag Filter: The boiler flue gases from cyclone separator enter into pack of bag

filters, where particulate matter will be separated leaving as cake on bags surface.

They are cleared by shaking or vibrating by pulse jet causing the filter cake to be

loosened and to fall in the Hopper.

iii) Boiler Stack: The adequate stacks of height 30 mtrs will be provided for

pollutants (SO2, NOx, PM & CO) dispersed in a very large area so that ground level

concentration is within CPCB permissible limits.

iv) Scrubbers: Two scrubbers of 2-Stage are proposed to scrub the HCl & SO2. The

packing media in the scrubber is 25 mm poly propylene rings.



3. BASELINE ENVIRONMENTAL STATUS

3.1 Study Area Included In Environmental Setting

Studies were carried out in about 10 km radius area from the site with respect to

meteorology, flora, fauna, land and socio-economies of the area. Further sampling

and analysis of air quality, water quality, noise level and soil quality were carried out.

The air quality, water quality, noise level and soil quality in the study area is

evaluated based on this physical sampling and analysis.

The base line data were monitored during the study period of Oct 2018 – Dec 2018.

The study team conducted site surveys and field experiments for gathering the

information on air quality, water quality, noise quality and soil quality.

3.2 CLIMATE OF THE STUDY AREA

A. Temperature:

During the study period the minimum and maximum temperatures were recorded as

12 °C and 39 °C respectively.

B. Relative Humidity:

During study period at project site during study period, the relative humidity was

recorded as 79%

C. Wind Pattern during Study Period

Dispersion of different air pollutants released into the atmosphere has significant

impacts on neighborhood air environment. The dispersion/dilution of the released

pollutant over a large area will result in considerable reduction of the concentration of

a pollutant. The dispersion in turn depends on the weather conditions like the wind

speed, wind direction, temperature, relative humidity, mixing height, cloud cover and

rainfall in the area.

Wind speed and direction data recorded during the study period is useful in

identifying the influence of meteorology on the air quality of the area. The following

observations can be made from the collected data;

Calm period is observed to be 1.9 % during the time of monitoring.

The predominant wind direction is N & NE.

Other than predominant wind directions wind was blowing in North direction.



Average wind speed 3.5 m/s.

Mostly the wind speeds are observed to be in the range of 5.7 – 8.8 m/sec,

0.5 – 2.1 m/Sec, 3.6 - 5.7 m/Sec, with frequency of distribution percentages

ranges from 27.5, 21.1, & 16.2.

D. Rainfall

Rainfall during the Study Period at the Project Site is 28.2 mm. Normal annual

rainfall is 982 mm. (Source: IMD Climatatological Normals, Nandigama 1981 - 2010)

3.3 SAMPLING LOCATION DETAILS

Total ten locations were selected for Base line status. Air, Water & Noise results are

presented in Table 8, 9 & 10 respectively.

3.4 AMBIENT AIR QUALITY

The ambient air monitoring was carried out for 24 hours a day, twice a week for 12

week per location in the study area. Ambient Air Quality Monitoring (AAQM) was

carried out at eight locations during period of Oct 2018 – Dec 2018.

1. Particulate Matter (PM10)

The maximum and minimum concentrations for PM10 were recorded in the study

area showed 98th percentile values in the range of 55.0 – 69.3 μg/ m3. The

maximum concentration 69.3 μg/ m3 were recorded at sampling locations at

Dondapadu (near Sitapurm). The concentrations of PM10 are well below the

CPCB standard of 100 μg/ m3.

2. Particulate Matter (PM2.5)

The CPCB Standard for concentration of PM2.5 is 60 μg/ m3. The maximum and

minimum 98th percentile concentrations for Particulate Matter (PM2.5) monitored

in the study area were 22.0 – 27.7 μg/m3 respectively. Highest value of 27.7 μg/

m3 was at Dondapadu (near Sitapurm). The concentration of PM2.5 is well below

the prescribed limit of 60 μg/ m3

3. Sulphur Dioxide (SO2)

98th percentile value of Sulphur dioxide in the study area from the monitored data

was in the range of 12.2 – 15.4 μg/ m3. Maximum value of Sulpur dioxide of 15.4



μg/ m3 obtained at Dondapadu (near Sitapurm). The concentration of SO2 is well

below the prescribed limit of 80 μg/ m3

4. Oxides of Nitrogen (NOx)

Ambient air quality status monitored for oxides of nitrogen in the study area were

in the range with 98th percentile values between 19.6 – 22.8 μg/ m3. A maximum

value of 22.8 μg/ m3 was prevailing at the time of sampling at Dondapadu (near

Sitapurm). The concentration of NOX is well below the prescribed limit of 80 μg/

m3

5. Carbon Monoxide (CO)

The maximum and minimum 98th percentile concentrations for Carbon Monoxide

(CO) monitored in the study area were 0.35 – 0.87 mg/m3 respectively. Highest

value of 0.87 mg/ m3 was at the Project Site. The concentration of CO is well

below the prescribed limit of 2 mg/ m3

6. Ammonia (NH3)

The maximum and minimum 98th percentile concentrations for Ammonia (NH3)

monitored in the study area were 24.9 – 28.1 μg/m3 respectively. Highest value of

28.1 μg/ m3 was at Dondapadu (near Sitapurm). The concentration of NH3 is well


7. Volatile Organic Compounds (VOCs)

Volatile Organic Compounds (VOCs) concentration in study area was found to be

Below Detectable Limit of 1 ppm.

The ambient air quality monitoring results indicates that the overall air quality in the

study area is within permissible standards prescribed by NAAQ Standards.



TABLE 8: THE MAXIMUM, MINIMUM & 98TH PERCENTILE VALUES FOR ALL THE

AMBIENT AIR SAMPLING LOCATIONS

Code Name of Sampling Location

PM 10(µg/M3) PM 2.5(µg/M

3) SO2(µg/M

3) NOX(µg/M

3) CO (mg/M

3) NH3 (µg/M

3)

Min Max 98th

Min Max 98th

Min Max 98th

Min Max 98th

Min Max 98th

Min Max 98th

A1 Project Site 59.1 66.3 66.3 23.7 26.5 26.5 13.1 14.7 14.7 20.5 22.1 22.1 0.66 0.87 0.87 25.8 27.4 27.4

A2 Dondapadu (near Sitapurm Colony)

58.2 69.6 69.3 23.3 27.8 27.7 12.9 15.5 15.4 20.3 22.9 22.8 0.21 0.58 0.57 25.6 28.2 28.1

A3 Mukteshwarapuram 52.9 58.9 58.7 21.2 23.6 23.5 11.8 13.1 13.0 19.2 20.5 20.4 0.11 0.51 0.44 24.5 25.8 25.7

A4 Bugga Madharam 53.4 60.2 59.7 21.4 24.1 23.9 11.9 13.4 13.3 19.3 20.8 20.7 0.12 0.36 0.35 24.6 26.1 26.0

A5 Vajinepalli 45.6 65.8 65.5 18.2 26.3 26.2 10.1 14.6 14.6 17.5 22.0 22.0 0.12 0.54 0.45 22.8 27.3 27.3

A6 Ramapuram 47.3 61.9 61.5 18.9 24.8 24.6 10.5 13.8 13.7 17.9 21.2 21.1 0.12 0.36 0.35 23.2 26.5 26.4

A7 Budavada 38.1 55.0 55.0 15.2 22.0 22.0 8.5 12.2 12.2 15.9 19.6 19.6 0.12 0.47 0.46 21.2 24.9 24.9

A8 Jaggayyapeta 57.2 62.0 61.8 22.9 24.8 24.7 12.7 13.8 13.7 20.1 21.2 21.1 0.12 0.36 0.36 25.4 26.5 26.4

NAAQ Standards 100 60 80 80 2 400



3.5 WATER QUALITY

Water sampling and subsequent analysis was carried out to determine both the

groundwater and surface water quality of the study area.

Ground water & Surface water samples were collected at 8 locations in the study

area. These samples were analyzed for physical and chemical parameters to

ascertain the Baseline status in the existing surface water and ground water bodies.

TABLE 9: WATER ANALYSIS RESULTS

S. No Parameters Ground water Surface water Min Max Min Max

1 pH 7.04 7.66 7.42 8.39 2 Total dissolved solids (mg/l) 608 966 414 954 3 Total hardness (mg/l) 295 515 190 495 4 Chlorides (mg/l) 102.2 257.4 62 265

5 Fluoride (mg/l) 1.1 6.2 2.6 7.2

6 Sulphates (mg/l) 66.5 98.6 35.4 84.8

Ground water samples collected was analyzed as per the Standard methods

and the water quality of the study area is found to be above the acceptable

limits of IS-10500, for parameters TDS, Total hardness, Total Alkalinity,

Calcium, Magnesium. Fluoride and Chloride.

3.6 NOISE ENVIRONMENT

Noise level monitoring was carried out at eight locations during the period of Oct –

Dec 2018.

Daytime Noise Levels (Lday)

Industrial Zone: The day time noise level at the Project site was 65.3 dB(A), which

is well below the permissible limits of 75 dB(A).

Commercial Zone: The daytime noise levels in the commercial location was

observed as 53.5 dB(A). The noise levels at all the locations were below the

permissible limits of 65 dB(A).

Residential Zone: The daytime noise levels in all the residential locations were

observed to be in the range of 52.2 dB (A) to 53.6 dB(A). The noise levels at all the

locations were below the permissible limits of 55 dB(A).



Night time Noise Levels (Lnight)

Industrial Zone: The night time noise level in the Project site was observed be 42.0

dB(A), which is well below the permissible limits of 70 dB (A).

Commercial Zone: The night time noise levels in the commercial location was



Residential Zone: The nighttime noise levels in all the residential locations were

observed to be in the range of 33.1 dB(A) to 37.6 dB(A). The noise levels were

below the permissible limits of 45 dB(A) in nighttime at all the locations.

TABLE 10: NOISE LEVELS OF THE STUDY AREA

S. No

Name of the

Location

Category of Area/zone

Day Time in Leq dB (A)

CPCB Standard Day Time

Night Time in Leq dB (A)

CPCB Standard

Night time

1. Project Site Industrial 65.3 75dB (A) 42.0 70dB (A)

2. Dondapadu Residential 53.4 55dB (A) 34.3 45dB (A)

3. Mukteshwarapuram Residential 53.5 55dB (A) 33.1 45dB (A)

4. Bugga Madharam Residential 52.8 55dB (A) 35.4 45dB (A)

5. Vajinepalli Residential 52.2 55dB (A) 37.5 45dB (A)

6. Ramapuram Residential 53.6 55dB (A) 37.6 45dB (A)

7. Budavada Residential 52.4 55dB (A) 37.5 45dB (A)

8. Jaggayyahpet Commercial 53.5 65dB (A) 36.1 55dB (A)

3.7 SOIL ENVIRONMENT

Based on the data, the soil quality is found to be normal.

3.8 LAND USE/ LAND COVER OF THE STUDY AREA

Land use / Land cover map is prepared by visual interpretation of high-resolution

satellite data (Satellite Imagery Acquisition: 11-September-2018) and with the help of

Survey of India Topographic maps on 1: 50,000 scale. Two seasons’ data (Khariff

year 2018) is used for the delineation of different units. The units are confirmed by

the ground truth/field visits.



TABLE 11: LAND USE / LAND COVER OF THE STUDY AREA

S. No LAND USE Area in Sq. km

Area in Percentage (%)

1 Built Up Land 23.550 7.5

2 Water Bodies 37.052 11.8

3 Forest 71.906 22.9

4 Crop Land 96.398 30.7

5 Waste Lands 85.094 27.1

Total 314.00 100.0

3.9 DEMOGRAPHIC AND SOCIO-ECONOMIC PROFILE

The total population of the study area is 1,80,636 in which male and female

population constitutes about 49.97 % and 50.03 % in the study area

respectively.

The literate male and female in the study area are 60324 and 48184 which

implies that the percentage of literacy rate is 66.83% with male and 53.32%

with female respectively.

In the study area the main and marginal workers are 76041 (42.1%) and

12056 (6.7%) respectively of the total population while the remaining 92539

(51.2%) constitutes non-workers

All the Villages, in the study area, are electrified – both for Domestic Purpose and

common facilities like, Street Lights, Public Water Pumping, etc. and provided with

Drinking Water.

4.0 IDENTIFICATION, PREDICTION & MITIGATION MEASURES

4.1 Expected Air Environment

A. PROCESS EMISSIONS DETAILS

The Predicted Process emissions are SO2, CO2, CH3Cl, HCl, HF, HBr, H2, NH3 & O2

which are liberated from manufacturing process of proposed products.

TABLE 12: PROCESS EMISSION DETAILS

S. No. Name of the Gas Quantity In

Kg/Day Treatment Method

1 Sulphur dioxide 251 Scrubbed by using C.S.Lye Solution

2 Hydrogen chloride 323 Scrubbed by using chilled water media

3 Hydrogen Bromide 75 Scrubbed by using C. S. Lye solution

4 Carbon dioxide 228 Dispersed into the atmosphere

5 Hydrogen 16 Diffused by using Nitrogen through



Flame arrestor

6 Ammonia 27 Scrubbed by using chilled water media

7 Oxygen 45 Dispersed into the atmosphere

8 Hydrogen fluoride 11 Scrubbed by using C.S.Lye Solution

9 Chloromethane 27 Scrubbed by using C.S.Lye Solution

4.2 PROPOSED PROCESS EMISSION CONTROL SYSTEM

Scrubbers with 300 mm (Diameter) X 3 meters (Height) & 300 mm (Diameter) X 3

meters (Height) capacities will be installed for control of process emissions. The

Schematic diagram of emission control system is given below.

FIGURE-1: SCHEMATIC DIAGRAM OF PROPOSED EMISSION CONTROL

SYSTEM

B. EMISSIONS FROM BOILER

The Particulate matter generated from 2 TPH & 3 TPH Coal fired Boilers will be

controlled by using cyclone separator followed by bag filters. The sulphur dioxide

(SO2) and oxides of nitrogen (NOX) from boiler will be dispersed in to atmosphere by

providing adequate stacks of height 30 mtrs each will be provided for effective

dispersion and dilution.

The predicted ground level concentrations when added to Baseline scenario, the

overall scenario levels of PM, SO2 and NOX are well within the permissible limits as

specified by NAAQ Standards.



TABLE 13: RESULTANT CONCENTRATIONS DUE TO

INCREMENTAL GLC's

Pollutant

Maximum

Baseline

Concentration

(μg/m3)

Incremental

Concentrations due

to Proposed Project

(μg/m3)

Resultant

Concentration

(μg/m3)

NAAQ

Standards

(μg/m3)

PM 69.3 0.975 70.275 100

SO2 15.4 2.34 17.74 80

NOx 22.8 2.59 25.39 80

4.3 Expected Effluent Water Details

The waste water generation will be 52.86 KLD which is from process, floor & reactor

washes, cooling tower blow down, boiler blow down, scrubber, DM plant and

domestic usage. The effluent generation and its HTDS & LTDS effluent details are

given below.

TABLE 14: EXPECTED EFFLUENT GENERATION DETAILS

S. No. Purpose Effluent

Details KLD

1 Process 28.36

2 Washings 5.00

3 Boiler Blow down 5.00

4 Cooling towers bleed off 7.00

5 Scrubbing System 3.00

6 Domestic 4.50

Total 52.86

TABLE 15: EXPECTED HTDS & LTDS EFFLUENT GENERATION DETAILS

Unit HTDS KLD

LTDS KLD

Effluent Generation

in KLD Treatment Method

Process 16.18 12.18 28.36 HTDS Effluent sent to stripper followed by MEE system. LTDS effluents treated in ETP along with MEE condensate. Treated effluent is sent to RO, RO permeate water is recycled and RO rejects taken for evaporation in MEE followed by ATFD to collect evaporation salts for disposal to TSDF.

Washings 0.00 5.00 5.00

Boiler Blow down 0.00 5.00 5.00

Cooling towers blow down 0.00 7.00 7.00

Scrubbing system 3.00 0.00 3.00

Domestic 0.00 4.50 4.50

Total 19.18 33.68 52.86



Effluent Treatment / Disposal: Zero Liquid Discharge (ZLD) concept consisting of

steam stripper, MEE system, ATFD, Biological Treatment and RO will be installed to

treat the effluents generated from plant and to reuse the treated water.

The MEE System with 40 KLD Capacity & RO system with 50 KLD Capacity will be

installed for treatment of effluents generated from plant operations.

4.4 Noise Environment

The main sources of noise pollution in the plant operations are Boiler, Reactors, DG

Set, compressors and other Noise generating units. Vehicular movements during

operation phase for loading / unloading of raw materials and finished products and

transporting activity may also increases the noise levels.

All the noise generating equipments like motors, gear boxes and compressors will be

regularly maintained with lubricating material to avoid noise generation. DG set will

be provided with acoustic enclosures. A thick greenbelt will be developed along the

periphery of the plant boundaries to minimize the noise pollution from the source.

4.5 Land Environment

The plant activities are unlikely to alter the land-use pattern in the project site. The

unit will take adequate measures for storage, handling and disposal of hazardous

waste. Hence, there will be no significant adverse impact on land environment.

4.6 Ecological Environment

Detailed flora and fauna studies were carried in the study area. As per baseline

studies, there are no endangered, threatened & protected plants and animal species

were recorded in the study area. Hence, no significant adverse impact is envisaged

on ecology.

4.7 Expected Hazardous and Solid Waste Details

The Hazardous and Solid waste generated and disposal methods from proposed

project are given below.



TABLE 16: EXPECTED HAZARDOUS & SOLID WASTE GENERATION,

DISPOSAL DETAILS

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

Hazardous Waste Details

1 Organic waste (Process Residue)

1406

Sent to Cement Industries

2 Spent Carbon 71

3 Solvent distillation residue 441

4 Organic Evaporate ( liquid from MEE stripper)

380

5 Spent Mixed Solvents 2 KL/Day SPCB Authorized Agencies for Reprocessing/Recycling

6 ETP Sludge 350 Sent to TSDF 7 Inorganic waste 504

8 MEE Salts 2868

9 Used Oils 500 Ltrs/Annum SPCB Authorized Agencies for Reprocessing/Recycling

10 Detoxified Containers 500 No’s/Month After Detoxification sent back to suppliers/sent to outside Parties

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

Solid Waste Details

12 Ash from boiler 5425 Sent to Brick Manufacturers

4.8. Risk Assessment and Disaster Management Plan

The Risk assessment studies have been conducted for identification of hazards, to

calculate damage distances and to spell out risk mitigation measures. The details

are discussed in detail in Chapter – 7 of EIA Report.

5.0 ENVIRONMENTAL MANAGEMENT PLAN

5.1 ENVIRONMENT MANAGEMENT PLAN FOR CONSTRUCTION PHASE

Adequate and effective environment protection measures will be planned and

designed to minimize the impacts due to activities related to pre-construction

(preparatory phase) of the project, machinery installation and commissioning stages

and end with the induction of manpower and start up. The impacts identified during

the construction phase are mainly due to site preparation, foundation work, material

handling, and construction of buildings and installation of the machinery.

All possible care will be taken to reduce the noise levels due to construction activity.

Also, noise prone activities shall be restricted to the extent possible during night



particularly during the period of 10 PM to 6 AM in order to have minimum

environmental impact.

5.2 ENVIRONMENT MANAGEMENT PLAN FOR OPERATIONAL PHASE

A) Air Pollution Management

The industry will take measures for reduction of fugitive emissions emanating

out of process reactions by providing vent condensers.

Good ventilation will be provided to reduce the workroom concentrations.

Fugitive emissions will be reduced by providing vent condensers to the all the

reactors.

Adequate stacks of height 30 Mtrs will be provided to 2 TPH & 3 TPH coal

fired boilers.

Stack monitoring facilities for the periodic monitoring of the stack to verify the

compliance of the stipulated norms. Apart from this Cyclone Separator, Bag

filters will be provided to the boiler.

In order to minimize the air pollution, unit will develop greenbelt in and around

its premises.

B) Water Pollution Management

Effluent generated in the plant will be treated in Proposed ZLD system.

The industry is proposing to install a MEE System with 40 KLD capacity,

Biological Treatment system of 55 KLD and RO system with 50 KLD

capacities for treatment of 52.86 KLD effluents generated from plant

operations.

Total Water requirement is 134.13 KLD out of which 43.50 KLD recycled

water recovered from ZLD system. The fresh water of 90.63 KLD will be met

from Ground Water source.

Unit is proposed to recharge ground water through roof water harvesting pits

in the project area and rain water harvesting pits outside plant area wherever

possible to balance the water table.

Use of high-pressure hoses for cleaning the floor and process equipment to

reduce the amount of wastewater generated during washings.



C) Noise Pollution Management

Noise suppression measures such as enclosures, buffers and / or protective

measures will be provided, if required.

Extensive oiling, lubrication and preventive maintenance will be carried out for

the machineries and equipments to reduce noise generation.

Greenbelt Development.

D) Hazardous & Solid Waste Management

To reduce the quantity of solid / hazardous waste generation as well as possible

contamination of land (soil) due to spillages / leaks from the plant operations,

following Mitigation measures are proposed:

There will not be any leakages / spillage from the raw-materials storage.

The generated Hazardous waste will be stored on floor with suitable packing

and this dedicated area will be covered with the roof.

The records on quantity of hazardous waste generation and disposal will be

maintained for each category and possibilities will be explored for

minimization and reuse.

E) Green Belt

Greenbelt will be developed in an area of 3.37 Acres (13660 Sq. m). The industry will

spend 4 Lakhs as capital cost for planting of samplings. Lists of plants suitable for

greenbelt as per the local agro climatic conditions are given in the EIA Report.

F) Solvent Recovery

Solvents will be recovered up to 95% using distillation column and necessary cooling

condensers.

5.3 ENVIRONMENT MANAGEMENT CELL

SGR Laboratories Pvt. Ltd. will have a dedicated Environmental Management Cell

with experienced staff to look after the proper environmental management of the

plant including operation & maintenance of all pollution control facilities.



5.4 ENVIRONMENT MONITORING PROGRAM

Regular monitoring of environmental parameters is of immense importance to

assess the status of environment during project operation. The regular monitoring

will be carried out with the MoEF&CC Registration / NABL Accredited Laboratory.

6. PROPOSED ROOF WATER HARVESTING

Roof top rainwater harvesting is one of the appropriate options for augmenting

ground water recharge/ storage in this industry.

The following table gives expected quantity of rain water harvesting using buildings

Roof top.

TABLE 17: AVAILABLE RAINWATER (ANNUAL) FOR HARVESTING

Description Area (m2) Rainfall

(m/Annum) Runoff

coefficient Total Rainwater

(m3/Annum)

Roof Area 8998 0.98 0.8 7054.43

Total available rainwater (in m3/annum) 7054

FIGURE-2: PROPOSED ROOF WATER HARVESTING STRUCTURE

7. EMP BUDGET

The unit has proposed for 110 Lakhs as capital cost and 15 Lakhs as recurring cost

for environment pollution control measures.



TABLE 18: PROPOSED BUDGET FOR ENVIRONMENTAL MANAGEMENT PLAN

[EMP]

S. No Particulars

Proposed

Capital Cost

(Rs. Lakhs)

Recurring

Cost

(Rs. Lakhs)

1

Pollution Control Equipment

(Scrubbers, Cyclone separator, Bag filter,

Sampling port arrangements etc.,)

20.0 2.0

2 ZLD System

(MEE, RO, ETP system) 80.0 7.5

3

Rain Water Harvesting

(Roof top water collection pit and Roof top water

towards the rain water harvesting pit)

3.0 0.5

4 Green Belt Development

(Plantation and Maintenance) 4.0 2.0

5 Health & Safety

(PPEs, Medical Surveillances Expenses etc.,) 3.0 1.0

6

Environmental Monitoring

(Air, Water, Noise, VOCs, Boiler Stack flue

gases, DG sets stack monitoring expenses etc.,)

0.0 2.0

Total 110 15

8.0 SOCIO-ECONOMIC DEVELOPMENT

It is predicted that socio-economic impact due to this project will positively increase

the chance of more employment opportunities for local people. There are no

Resettlement and Rehabilitation issues involved in this project. The project

infrastructures will be of use to people of the area. The revenue of the village will be

definitely increased due to the proposed project.

9.0 PROJECT BENEFITS

Proposed project will result in considerable growth and upliftment of local community

in the nearby villages by providing the employment. The project will generate direct

and indirect employment to the nearby villages and the unavailable technical

persons will be recruited from outside.

10.0 CONCLUSION

SGR Laboratories Pvt. Ltd. has committed to implement all the pollution control

measures to protect the surrounding environment – adapting Zero-Liquid-Discharge



System for all its Effluents, by controlling process emissions and Safe-Disposal of all

Solid Wastes – generated either as process wastes or packing wastes.

The project can definitely improve the regional, state and national economy.

Industrial growth is an indication of all-round Socio-Economic Development – by

generating local Employment and Business Opportunities. The implementation of

this project will definitely improve the physical and social infrastructure of the

surrounding area.

CHAPTER -I

INTRODUCTION

Draft EIA Report SGR Laboratories Pvt. Ltd.

Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter - I Page 1

CHAPTER- I

INTRODUCTION

1.1 PURPOSE OF THE REPORT

As per the EIA Notification dated 14th September 2006 and its amendments from time to

time, the project falls under 5(f) “A” category and requires Environmental Clearance. The

industry engaged the services of Rightsource Industrial Solutions Pvt. Ltd, Hyderabad to

prepare and submit the necessary documents. The consulting firm has submitted an

application in prescribed FORM-I along with necessary enclosures for obtaining Terms of

Reference to MoEF&CC, GOI, New Delhi.

On 17th March, 2018 ToR application was submitted, mentioning the Sy.No. 299 and its

parts instead of Sy.No. 290 and its parts and Standard ToR were granted by MoEF & CC

on 19th April, 2018. Based on granted ToR we have carried out the baseline monitoring

during the period of October to December– 2018.

Due to change in Survey no., on 05th Jan, 2019 we have applied Fresh ToR application as

suggested by MoEF&CC, mentioning the Sy. No. 290 and its parts and also communicated

for utilizing the collected baseline data during the period from October to December –

2018.

The project proposal was accepted by MoEF&CC and issued Standard Terms of Reference

vide F. No: IA-J-11011/14/2019-IA II (I) Dated on 13th Feb 2019, to carryout EIA Study.

Draft EIA Report was prepared and submitted for Public Consultation.

1.2 IDENTIFICATION OF PROJECT & PROJECT PROPONENT

1.2.1 IDENTIFICATION OF THE PROJECT

SGR Laboratories Pvt. Ltd. has registered office located at Plot No.108, SVCIE, IDA,

Jeedimetla, Hyderabad -500055, Telangana State. Industry proposed to establish Bulk

Drugs & Intermediates Manufacturing Unit at Sy No: 290 and parts, Dondapadu (V)

Chinthalapalem (M), Suryapet District, Telangana state.

The manufacturing unit is in an area of 9.0 Acres (36414 Sq. m). The proposed project cost

is about Rs. 12 Crores will be used for construction and operational phase.



1.2.2 ABOUT THE PROMOTERS

A. Koti Reddy, Director, studied B. Sc and having 30 years experience in Chemical

Industry.

R. Venkata Manikanta, Partner, studied B. Tech (Mechanical Engineering) and having

experience in Maintenance Department.

Dr. A. Kavitha, Partner, studied MBBS and having 10 years of experience.

K. Rameshbabu Partner, studied B. Sc and having 35 years experience in various

Industries.

R. Raghavendra, Partner, studied B. Tech (Electrical Engineering) and having 9 years

experience in Software Company.

1.3 OBJECTIVE OF THE STUDY

The objective of the study is to carry out Environmental Impact Assessment (EIA) for the

proposed project to meet the Environmental compliances laid down by the Ministry of

Environment, Forest and Climate Change (MoEF&CC) Government of India. Ministry

issued a circular making it mandatory to obtain Environment Clearance for 65 categories of

industries. Bulk Drugs & Intermediates is one of them, occupying 5th place.

The study would include the description of project setting, appraisal of project activities and

assessment of adverse impacts related to the location, design, construction and operation

of the project. Environmental Management Plan (EMP) will be prepared that includes

mitigation measures, including evaluation of alternatives to reduce or mitigate/eliminate the

impacts that likely to cause most significant environmental burdens. As per the above

notification the industry seeks Environment Clearance from MoEF&CC, GOI, New Delhi.

Preparation of Environmental Impact Assessment Report (EIA) based on one season

(Three Months) data, which would be used as management planning tool for better

Environmental Management by suggesting control measures to avoid pollution problems

arising out of the project. The report will include a detailed Environmental Management

Plan (EMP). The study will be carried out incorporating all the details and requirements of

State Pollution Control Board (SPCB) and Ministry of Ministry of Environment, Forest and

Climatic Change as per their requirements.



1.4 BRIEF DESCRIPTION OF THE PROJECT

1.4.1 NATURE OF THE PROJECT

SGR Laboratories Pvt. Ltd. proposed to establish Bulk Drugs & Intermediates

manufacturing unit. The proposed project falls under 5(f) “A” category of Synthetic Organic

Chemicals Industry as per EIA Notification, 2006 and its amendment thereof and requires

Environmental Clearance.

1.4.2 SIZE OF THE PROJECT

The industry proposed to establish manufacturing unit in an area of 9.0 Acres (36414 Sq.

m). The proposed project cost is about Rs. 12 Crores, which includes construction and

operational cost.

SGR Laboratories Pvt. Ltd. is proposed for manufacture the below mention products with

Manufacturing Capacity of 81 TPM. The list of proposed products is shown in Table 1.1.

Table 1.1: Proposed Products and Quantities

S. No Name of the Product Quantity in

Kg/Month CAS Number

Therapeutic Category












Total 81000



in Kg/Day



313.57

3 Duloxetine Hydrochloride Isomer for product Recovery 98.75

Mandelic acid 80.79



1.4.3 LOCATION OF THE PROJECT

SGR Laboratories Pvt. Ltd. proposed to establish Bulk Drugs & Intermediates

Manufacturing Unit at Sy No: 290 & Parts, Dondapadu Village, Chinthalapalem Mandal,

Suryapet District, Telangana state.

TABLE 1.3: PROJECT LOCATION AND COMPLIANCE OF SITE



Climatic Conditions

Annual Max Temp is 44.5 0C Annual Min Temp is 12.7 0C Normal Annual Rainfall is 982 mm (Source: IMD Climatalogical Normals, 1981 - 2010)





National Highway National Highway No. 9 – 16 km (ENE) (Hyderabad – Vijayawada Road)

Railway station Motumari Railway Station – 33 km (ENE)

Airport Vijayawada Airport – 87 km (ESE)

Interstate Boundary Telangana State – Andhra Pradesh Interstate Boundary – 400 meters (NE)

Major Industries near the plant site

1. Zuari cement 2. Sitapuram Power Plant 3. KCP Cement 4. Anjani Portland Cement Limited 5. Ra Chem Pharma Limited 6. Sri Durga Industries 7. Ultratech Balaji Cement works 8. Ultratech Cement Limited 9. Jaypee Balaji Cement Plant

National Parks None within 10 Km radius

Wild life sanctuary None within 10 Km radius


Water Bodies within 10 km radius

Krishna River – 2.5 km (ESE) Palleru River – 5.5 km (E) Pulichintala Dam – 5.9 km (S) Water body near Jaggayyapet – 8.3 km (NE) Water body near Ramapuram – 8.0 km (WNW)


Budavada R.F- 2.8 km (N) Balusupadu R.F – 6.0 km (N) Jaggayyapeta Extension R.F – 5.8 km (E) Kuntimadi R.F- 5.2 km (ESE) Ginjupalle R.F- 6.4 km (SE) Venkatayapalem Extension R.F- 6.0km (SE)



1.4.4 PROJECT AND ITS IMPORTANCE TO THE COUNTRY & REGION

SGR Laboratories Pvt. Ltd. is a Greenfield project intended to establish manufacturing

unit of Bulk Drugs & Intermediates.

Availability of the well-connected road and railway network for easy transportation of

the construction equipments and materials, Raw materials and finished products.

Easy availability of skilled and unskilled labor for construction of Plant and its

operation.

India’s pharmaceutical sector accounts for about 2.4 per cent of the global pharmaceutical

industry in terms of value and 10 per cent in terms of volume. India accounted for about 20

per cent of the global exports in generics. In FY16, India exported pharmaceutical products

worth USD $ 16.89 billion, with the number expected to reach USD $ 40 billion by 2020.

India’s healthcare sector, one of the fastest growing sectors, is expected to advance at a

CAGR of 17 per cent to reach USD $ 250 billion by 20. The generics market stood at USD

$ 26.1 billion in 2016 from USD $ 21 billion in 2015. India’s generics market has shown an

immense potential for future growth.

1.5 SCOPE OF THE STUDY

1.5.1 ENVIRONMENTAL IMPACT ASSESSMENT

To assess the impact of the project on Land use, Ambient Air Quality, Water Quality,

Noise levels, Ecology & Biodiversity, Hydrology & Geology, and Socio- economic

status of area.

To prepare Environmental Management Plan (EMP) for mitigating adverse impacts

due to proposed project.

Collection and testing of water sources and soil.

To prepare environmental monitoring plan for operational phase.

Greenbelt development.

1.5.2 SOCIO-ECONOMIC ASSESSMENT

This Study Report covers Population, Gender Ratio, Rural & Semi-Urban Demographic

Distribution, Literacy Rate and Social Amenities available in the study Area like, Transport,

Sanitation, Drinking Water, Medical & Health Facilities, Employment Rate and other

Venkatayapalem R.F- 5.8 km (SSE) Nemalipuri R.F – 7.6 km (SSW) Chintapalem R.F – 7.6 km(SSW)



Developmental Indices of Villages falling within the 10 Km radius of the Proposed Project

site.

1.5.3 REGULATORY FRAMEWORK

The MoEF&CC, CPCB and SPCBs together form the regulatory and administrative core of

the sector. Legislation for environmental protection in India for chemical industry is mainly

EIA Notification- 2006, Water (Prevention & Control of Pollution) Act -1974, Air (Prevention

& Control of Pollution) Act, 1981, Water (Prevention and Control of Pollution) Cess Act,

1977 Hazardous Waste (Management, Handling and Transboundary Movement) Rules,

2016, amended time to time etc are major Act/rules/notification applicable to industry.

1.5.4 REGULATORY SCOPING

Obtaining Consent for Establishment & Consent for Operation from State

Pollution Control Board.

1.6 LEGAL POLICY AND INSTITUTIONAL FRAMEWORKS

The principal environmental regulatory authority is the Ministry of Environment, Forest and

Climatic Change (MoEF&CC), New Delhi which formulates environmental policies and

accords environmental clearances for different projects. Table 1.2 highlights the relevant

environmental legislations applicable to this project.

TABLE 1.4: APPLICABILITY OF LEGAL POLICIES TO THE PROJECT

S. No

Legal frame work coordinating

authority Objectives of the policy

Applicability to the project

Environmental Legality

1 Water (Prevention and Control of pollution) Act, 1974

SPCB

Prohibits the discharge of pollutants into water bodies beyond a given standard, and lays down penalties for non-compliance

Applicable

2 Water (Prevention and Control of Pollution) Cess Act, 1977

SPCB Provides for a levy and collection of a cess on water consumed by industries and local authorities

Applicable

3 Air (Prevention and Control of Pollution) Act, 1981

SPCB Provides means for the control and abatement of air pollution.

Applicable

4 The Air (Prevention and Control of Pollution) Rules, 1982

SPCB

Defined the procedures for conducting meetings of the boards, the powers of the presiding officers, decision-making etc

Applicable



S. No

Legal frame work coordinating

authority Objectives of the policy

Applicability to the project

5 Public Liability Insurance Act, 1991

Director of Factories

An act to provide for public liability insurance for the purpose of providing immediate relief to the persons affected by accident occurring while handling any hazardous substance and for matters connected herewith or incidental thereto

Applicable

6

Environment (Protection) Act, 1986 (EPA) followed by amendment in May 1994 (Schedule-I)

(MoEF&CC)

Ensure that appropriate measures are taken to conserve and protect the Environment before commencement of operations.

Applicable

7 Environmental Impact Assessment Notification no. S.O. 1533

MoEF&CC

Under its ambit, 32 types of industries are liable to opt for Environmental clearance from MoEF&CC by providing adequate EIA report

Applicable

8 The Environment (Protection) Rules, 1986

SPCB Lay down the procedures for setting standards of emission or discharge of environmental pollutants

Applicable

9

The Hazardous Wastes management (Management and Handling) Rules, 1989 and amended in 2000

SPCB

Procedure for inventory, control, handling and disposal of hazardous waste. Provide for setting up of disposal sites/landfill sites design, operation and closure

Applicable

10 Solid Waste Management Rules, 2016

SPCB Procedure for management and handling of solid wastes

Applicable

11

Batteries (Management and Handling) Amendment Rules, 2010

SPCB To ensure that the used batteries are collected back as per the schedule against new batteries

Applicable

12 E- Waste (Management Rules), 2016

SPCB Procedure to recovery/and/or reuse of useful material from waste electrical and electronic equipment

Applicable

PROJECT DESCRIPTION

CHAPTER -II


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter - II Page 8

CHAPTER-II

PROJECT DESCRIPTION

2.1 TYPE OF THE PROJECT

SGR Laboratories Pvt. Ltd. is proposed to establish Bulk Drugs & Intermediates

Manufacturing Unit at Survey No. 290 & Parts, Dondapadu Village, Chinthalapalem

Mandal, Suryapet District, Telangana state.

The industry proposes to establish manufacturing unit in an area of 9.0 Acres (36414

Sq. m). The Industry is having its registered office at Plot No.108, SVCIE, IDA,

Jeedimetla, Hyderabad - 500055, Telangana State.

The proposed project cost is about Rs. 12 Crores, which includes construction and

operational cost.

2.2 NEED FOR THE PROJECT

India’s healthcare sector, one of the fastest growing sectors, is expected to advance

at a compounded annual growth rate (CAGR) of 17 per cent to reach USD$ 250

billion by 2020. The generics market stood at USD$ 26.1 billion in 2016 from USD $

21 billion in 2015. India’s generics market has shown an immense potential for future

growth. Hence, the proponent has decided to expand an existing Bulk drugs industry

in this location keeping in view of Low cost manpower, Semi–skilled and un-skilled

labor availability.

2.3 LOCATION

The proposed site is located at Sy No: 290 & Parts, Dondapadu (V), Chinthalapalem

(M), Suryapet District, Telangana state. It has good connectivity and infrastructure

availability. Dondapadu to Muktyala road is at a distance of 0.4 Km (NE), National

Highway No. 9 is at a distance of 16 km (ENE); the proposed site is located about

1.30 Km from Dondapadu village. The Motumari Railway Station is at distance of 33

km (ENE). Vijayawada Airport is about 87 km (ESE) from the project site.

The industry proposes to establish manufacturing unit in an area of 9.0 Acres (36414

Sq. m). The co-ordinates of the Project site are Latitude: 16°49' 33.67" N, Longitude:

80° 2' 53.39" E. The land usage details are given in Table 2.1.



TABLE 2.1: LAND USE DETAILS

S. No. DESCRIPTION AREA IN Sq. m AREA IN Acres AREA IN %

1 Total Built up Area 8998 2.22 24.71

2 Green Belt Area 13660 3.37 37.51

3 Roads Area 8925 2.21 24.51

4 Open Area 4831 1.20 13.27

TOTAL 36414 9.00 100.00

**37.51 % of Land Allotted For Green Belt Development



FIGURE 2.1: LOCATION MAP

SGR Laboratories Pvt. Ltd. Sy No. 290 & Parts, Dondapadu (V) Chinthalapalem (M), Suryapet (D), Telangana State



FIGURE 2.2: GOOGLE EARTH MAP SHOWING SGR LABORATORIES PRIVATE LIMITED



FIGURE 2.3: LATEST PHOTOGRAPHS OF PROJECT SITE



FIGURE 2.4: TOPO MAP SHOWING 10 KM RADIUS



FIGURE 2.5: SITE LAYOUT



2.4 SIZE AND MAGNITUDE OF OPERATION

Total production capacity of proposal is 81 TPM.

TABLE 2.2: List of Proposed Products and Quantities

S. No Name of the Product Quantity in

Kg/Month CAS Number

Therapeutic Category












Total 81000



in Kg/Day



313.57

3 Duloxetine Hydrochloride

Isomer for product Recovery 98.75

Mandelic acid 80.79

2.5 PROPOSED SCHEDULE FOR APPROVAL AND IMPLEMENTATION

The industry intends to obtain approval within one year and to implement the

recommendations. The industry proposes to implement the recommendations of the

Authorities. The MoEF&CC has given Terms of Reference vide F. No: IA-J-

11011/14/2019-IA-II (I) Dated on 13th Feb 2019, to carryout EIA Study. The

Environmental monitoring and analysis were carried out during the period of Oct –

2018 to Dec – 2018 and Draft EIA Report was prepared and submitted for Public

Consultation.



The Environmental Clearance is expected to get after public consultation in four to

five months.

The proponent after receiving the EC will approach SPCB to get CFE/CFO and other

statutory approvals from respective authorities for plant operations.

2.6 TECHNOLOGY AND PROCESS DESCRIPTION

The manufacturing process of Bulk Drugs & Intermediates consists of chemical

synthesis extending to stages of processing involving different types of chemical

reactions. The unit will take adequate control measures for storage and handling of

Raw materials, solvents and gas cylinders within factory premises. The proponent is

having proven technology to manufacture the proposed products.



2.6.1 MANUFACTURING PROCESS OF THE PRODUCTS

ATORVASTATIN CALCIUM TRIHYDRATE

Process Description

Stage-1

(6-Cyanomethyl-2, 2-dimethyl- [1, 3] dioxan-4-yl)-acetic acid tert-butyl ester

undergoes hydrogenation in presence of Raney Nickel and Methanol to give Stage-1

product.

Stage-2

Stage-1 reacts with 4-(4-fluorophenyl)-2-isobutyryl-3 phenyl-4-oxo-N-phenyl-

butyramide in presence of IPA and Cyclohexane to give Stage-2 product.

Stage-3

Satge-2 undergoes hydrolysis in presence of Hydrochloric acid and IPA to give

stage-3 product.

Sateg-4

Stage-3 product reacts with Calcium acetate in presence of Methanol and toluene to

give Atorvatatin calcium Trihydrate

Route of Synthesis

Stage-1

O

OOO

NC

O

OOO

H2N

+ 2 H2

(6-Cyanomethyl-2,2-dimethyl-[1,3]dioxan-4-yl)-acetic acid

tert-butyl ester

C14H23NO4

269.34

4.00[6-(2-Amino-ethyl)-2,2-dimethyl-

[1,3]dioxan-4-yl]-acetic acid tert-butyl ester

C14H27NO4

273.37



Stage-2

O

OOO

H2N

[6-(2-Amino-ethyl)-2,2-dimethyl-[1,3]dioxan-4-yl]-acetic acid

tert-butyl ester

C14H27NO4

273.37

NNH

F

OCH3

H3COO

H3CCH3

O

O

+

O

HN

O

O

F

+ 2 H2O

2-[2-(4-Fluoro-phenyl)-2-oxo-1-phenyl-ethyl]-4-methyl-3-oxo-pentanoic acid phenylamide

C26H24FNO3

417.47

(6-{2-[2-(4-Fluoro-phenyl)-5-isopropyl-3-phenyl-4-phenylcarbamoyl-pyrrol-1-yl]-ethyl}-2,2-dimethyl-[1,3]dioxan-4-yl)-

acetic acid tert-butyl esterC40H47FN2O5

654.81

2X18=36.0

Stage-3

NNH

F

OCH3

H3COO

H3CCH3

O

O

(6-{2-[2-(4-Fluoro-phenyl)-5-isopropyl-3-phenyl-4-phenylcarbamoyl-pyrrol-1-yl]-

ethyl}-2,2-dimethyl-[1,3]dioxan-4-yl)-acetic acid tert-butyl ester

C40H47FN2O5

654.81

H2O

NNH

F

OCH3

H3C OHHO

O

O

+

+

18.0 7-[2-(4-Fluoro-phenyl)-5-isopropyl-3-phenyl-4-phenylcarbamoyl-pyrrol-1-yl]-3,5-dihydroxy-heptanoic acid tert-butyl

esterC37H43FN2O5

614.75

O

Acetone

58.08



Stage-4

NNH

F

OCH3

H3C OHHO

O

O

7-[2-(4-Fluoro-phenyl)-5-isopropyl-3-phenyl-4-phenylcarbamoyl-pyrrol-1-yl]-3,5-

dihydroxy-heptanoic acid tert-butyl ester

C37H43FN2O5

2X614.75=1229.5

+ Ca(COOCH3)2

(158.17)

+ 3 H2O

54.0

NNH

F

OCH3

H3COHOH

O-

O

2

Ca+2. 3H2O

(1209.26)

+ OH2

(148.24)

+ 2 CH3COONa

(164)

+

(80)

2 NaOH

2

Atorvastatin calcium trihydrate2-Methyl-propan-2-ol Sodium acetate

Flow Chart

Stage-1

Stage-2

Stage-3

Stage-4

ATORVASTATIN CALCIUM TRIHYDRATE

(6-Cyanomethyl-2,2-dimethyl- [1,3]dioxan-4-yl)-acetic acid tert-butyl esterRaney NickelMethanol

Methanol Recspent catalyst

Stage-14-(4-fluorophenyl)-2-isobutyryl-3 phenyl-4-oxo-N-phenyl-butyramide cyclohexaneIsopropylalcohol

Cyclo hexane RecIsopropyl alcohol Rec

Stage-2Sodium carbonateAcetonitrileIPAHydrochloric acid

Acetonitrile RecIPA Rec

Stage-3Calcium acetate Sodium hydroxide flakes Hydrochloric acidMethanolToluene

Methanol RecToluene Rec



Material Balance:

Material balance of Atorvastatin calcium Trihydrate Stage-1

Batch Size: 500.0Kg

Name of the input Quantity in Kg

Name of the out put Quantity In Kg

(6-Cyanomethyl-2,2-dimethyl- [1,3]dioxan-4-yl)-acetic acid tert-butyl ester

252.00 Stage-1 248.00

Hydrogen 0.68 Methanol Recovery 152.00

Raney Nickel 1.00 Methanol Loss 8.00

Methanol 160.00 Spent catalyst 1.00

Organic residue 4.68

Process residue-4.68

Total 413.68 Total 413.68


Batch Size: 500.0Kg



Stage-1 248.00 Stage-2 570.00

4-(4-fluorophenyl)-2-isobutyryl-3 phenyl -4-oxo-N-phenyl-butyramide

378.50 Generated water 32.48

Pivalic acid 2.00 Cyclohexane Recovery 190.00

cyclohexane 200.00 Cyclohexane Loss 10.00

Isopropylalcohol 150.00 Isopropylalcohol Recovery 143.00

Isopropylalcohol Loss 7.00

Organic residue(Pivalic acid) 26.02

Process residue-26.02 (organic impurities-24.02, Pivalic acid-2)



Batch Size: 500.0Kg



Stage-2 570.00 Stage-3 522.00

Sodium carbonate 7.00 Acetonitrile Recovery + Acetone-50.16

335.16

Acetonitrile 300.00 Acetonitrile Loss 15.00

IPA 150.00 IPA Recovery 143.00

Water 2000.00 IPA Loss 7.00

Effluent water 1991.60

(water-1984.60, Sodium carbonate-7)

0



Organic Residue 13.24


Total 3027.00 Total 3027.00


Batch Size: 500.0Kg



Stage-3 522.00 Atorvastatin calcium Trihydrate

500.00

Calcium acetate 66.82 Methanol Recovery 280.00

Sodium hydroxide flakes 33.95 Methanol Loss 15.00

Hydrochloric acid 3.36 Toluene Recovery 185.00

Methanol 300.00 Toluene Loss 10.00

Toluene 200.00 Effluent water 1549.98

Activated carbon 5.00 (water-1477.56,sodium acetate-69.42,Toluene-3)

0

Hyflow 3.00 Spent carbon & Hyflow 8.00

Water 1500.00 Organic residue 86.15

Process residue-79.15 Organic Impurities-16.51,2-Methyl-propan-2-ol-62.64, Distillation residue-7 (Toluene-2, Methanol-5)

Total 2634.13 Total 2634.13

DAPOXETINE HYDROCHLORIDE

Process Description:

Stage-1

1-Napthol reacts with 3-Phenyl propyl bromide and Potassium hydroxide in the

presence of Methanol to give Stage-1 product.

Stage-2

Step-A

Stage-1 product reacts with N-Bromosuccinimide in the presence of EDC to give

Stage-2A product.

Step-B

Step-2A product reacts with Di methyl amine in the presence of Ethanol to give

Stage-2B product.

Stage-3

Stage-2 B product reacts with Tartaric acid in the presence of Ethanol to give Stage-

3 product.



Stage-4

Stage-3 product reacts with IPA. HCl to give Dapoxetine Hydrochloride .

Route of Synthesis:

Stage-1 OH

1-Napthol

C10H8O

144.17

+ Br

3-phenyl propyl bromide

C9H11Br

199.09

+ KOH

Potassium hydroxide

56.11

Methanol

O

1-(3-Phenyl-propoxy)-naphthalene

C19H18O

262.35

+ KBr

119.00

+ H2O

18.0

Stage-2

Step-A

O

1-(3-Phenyl-propoxy)-naphthalene

C19H18O

262.35

+

N-Bromo succinimide

OON

Br

C4H4BrNO2

177.98

EDC

O

Br

1-(3-Bromo-3-phenyl-propoxy)-naphthalene

C19H17BrO

341.24

+

OO

HN

Pyrrolidine-2,5-dione

C4H5NO2

99.09



Step-B

O

Br

1-(3-Bromo-3-phenyl-propoxy)-naphthalene

C19H17BrO

341.24

+

Dimethyl amine

HN

C2H7N

45.08

Ethanol

O

N

Dimethyl-[3-(naphthalen-1-yloxy)-1-phenyl-propyl]-amine

C21H23NO

305.41

+ HBr

80.91

Stage-3

O

N

Dimethyl-[3-(naphthalen-1-yloxy)-1-phenyl-propyl]-amine

C21H23NO

305.41

+

Tartaric acid

OH

OHO

HO

O

OH

C4H6O6

150.09

O

N

OH

OHO

HO

O

OH

Dimethyl-[3-(naphthalen-1-yloxy)-1-phenyl-propyl]-amine tartarsate

C25H29O7N

455.50



Stage-4

O

N

OH

OHO

HO

O

OH

Dimethyl-[3-(naphthalen-1-yloxy)-1-phenyl-propyl]-amine tartarsate

C25H29O7N

455.50

IPA.HCl

O

N HCl

Dapoxetine Hydrochloride

C21H23NO

305.41

OH

OHO

HO

O

OH+

Tartaric acid

C4H6O6

150.09

Flow Chart:

1-Naphthol3-Phenylpropyl bromidePotassium hydroxideMethanol

Stage-1 Methanol Rec

Stage-2 Ethanol RecDiethyl ether Rec

Stage-1Di methyl amineEthanolDiethylether

Stage-3 Ethanol Rec

Stage-2EthanolTartaric acid

Stage-4 Ethyl acetate Rec

Stage-3Sodium hydroxideEthyl acetateIPA.HCl




Material Balance:

Material balance of Dapoxetine Hydrochloride Stage-1

Batch Size:100.00 Kg



1-Naphthol 106.00 Stage-1 187.00

3-Phenylpropyl bromide 147.00 Methanol Recovery 251.00

Potassium hydroxide 42.00 Methanol Loss 13.00

Methanol 265.00 Diethyl ether Recovery 333.00

Diethyl ether 350.00 Diethyl ether Loss 17.00

Sodium sulphate 20.00 Carbon tetra hydrochloride Recovery

238.00

Carbon tetra hydrochloride 250.00 Carbon tetra hydrochloride Loss 12.00

Water 500.00 Effluent water 600.72

(Water-500,Generated water-

13.23,Potassium bromide-87.49) 0

Inorganic solid waste 20.00

(Sodium sulfate) 0


Process residue-7.28 Distillation residue-1 (Methanol-1)

Total 1680.00 Total 1680.00





Stage-1 187.00 Stage-2 206.00

Di methyl amine 32.00 Ethanol Recovery 665.00

Ethanol 700.00 Ethanol Loss 35.00

Diethyl ether 700.00 Diethyl ether Recovery 665.00

Sodium sulphate 20.00 Diethyl ether Loss 35.00

N-Bromo succinamide 127.00 Effluent water 800.00

water 800.00 (Water-800) 0


(Sodium sulfate) 0

Process emission 56.19

(Hydrogen Bromide-56.19) 0

Organic Residue 0

Succinimide Recovery 70.63



Total 2566.00 Total 2566.00







Stage-2 206.00 Stage-3 153.00

Ethanol 100.00 Ethanol Recovery 95.00

Tartaric acid 51.00 Ethanol Loss 5.00

Isomer recovery 104.00

Organic Residue






Stage-3 153.00 Dapoxetine Hydrochloride 100.00

Sodium hydroxide 1.00 Ethyl acetate Recovery 90.00

Ethyl acetate 100.00 Ethyl acetate Loss 10.00

IPA.HCl 2.00 Effluent water 851.40

Water 800.00 (Water-800,Tartraic acid-50.40,

Sodium Hydroxide-1) 0


Process residue-4.6

Total 1056.00 Total 1056.00

D-PENICILLAMINE

Process description:

Stage-1

The Penilloic acid is reacted with the mixture of Aniline, Water, Acetic acid and

Toluene medium , and extracting the product in to aqeous layer to give D-

Penicillamine crude. The obtained crude is crystallized with methanol to give Pure D-

Pencillamine



Route of Synthesis:

Stage-1

HN

OHN

SCH3

CH3

OOH

Penilloic acid

C15H20N2O3S

308.39

+

NH2

Aniline

C6H7N

93.13

Methanol, Toluene, EDC, Acetic acid & Water

H3C

HS

CH3

OH

O

NH2H

D-PenicillamineC5H11NO2S

149.21

+

HN

O

N

2-Phenyl-N-(2-phenylimino-ethyl)-acetamide

C16H16N2O

252.31Flow chart:

Stage-1

Peniloic acidAnilineMethanolTolueneEDCAcetic acidActivated carbonHyflow Water

Methanol + Toluene (Mixed Solvents)RecoveryEDC RecoveryEffluent water

D-Penicillamine

Material balance:

Material Balance of D-Penicillamine Stage-1

Batch Size:200.00Kg


Name of the out put Quantity in Kg

Peniloic acid 460.00 D-Penicillamine 200.00



Aniline 139.00 By-Product (2-Phenyl-N-(2-phenylimino-ethyl)-acetamide)

376.28

Methanol 400.00 Methanol + Toluene (Mixed Solvents)Recovery

718.00

Toluene 350.00 Methanol loss 10.00

EDC 300.00 Toluene loss 12.00

Acetic acid 89.55 EDC Recovery 295.00

Activated carbon 15.00 EDC loss 5.00

Hyflow 1.00 Effluent water 2503.00

Water 2500.00 (Water-2500,Toluene-3) 0

Spent carbon 15.00

Inorganic solid waste (Hyflow)

1.00

Spent acetic acid 89.55


Process residue-22.72 Distillation residue-7 (Methanol-5,Toluene-2)

Total 4254.55 Total 4254.55

DULOXETINE HYDROCHLORIDE


Stage-1

3-Dimethylamino-1-thiophen-2-yl-propan-1-ol reacts with Mandalic acid in the

presence of Ethyl acetate to give Stage-1 product.

Stage-2

Stage-1 product undergoes reaction with Sodium carbonate in the presence of MDC

to give Stage-2 product.

Stage-3

Stage-2 product reacts with 1-Fluoro naphthalene, Oxalic acid in the presence of

DMSO to give Stage-3 product.

Stage-4

Stage-3 product reacts with Phenyl chloro formate in the presence of Toluene a to

give Stage-4 product.

Stage-5

Stage-4 product reacts with Hydrochloric acid in the presence of Ethyl acetate to

give Duloxetine Hydrochloride product.



Route of synthesis:

Stage-1:

SN

CH3

CH3

OH

SN

CH3

CH3

+

OHO

OH

OHO

OH

3-Dimethylamino-1-thiophen-2-yl-propan-1-ol

C9H15NOS

2 X185.29 = 370.58

L(+)-Mandelic acid

C8H8O3

152.15

3-Dimethylamino-1-thiophen-2-yl-propan-1-ol,Mandelate

C17H23NO4S

337.43

Ethyl acetate

OH

2

SN

CH3

CH3

OH

Isomer

185.30

+

Stage-2:

SN

CH3

CH3

OH

OHO

OH

3-Dimethylamino-1-thiophen-2-yl-propan-1-ol,Mandelate

C17H23NO4S

337.43

MDC

10%Na2CO3 SN

CH3

CH3

OH

OHO

OH

+


C9H15NOS

185.29

C8H8O3

152.15

Mandelic acid



Stage-3: Step-A:

SN

CH3

CH3

OH


C9H15NOS

185.29

+

F

1-Fluoro-naphthalene

C10H7F

146.16

NaOH

DMSO

SN

CH3

CH3

O

C19H21NOS

311.44

+ HF

Hydrofluoride

20.01

Dimethyl-[3-(naphthalen-1-yloxy)-3-thiophen-2-yl-propyl]-amine

Step-B:

+

Oxalic acid

O OH

OHO

C2H2O4

90.03

NaOH

DMSO

SN

CH3

CH3

OO OH

OHO

C21H23NO5S

401.48

Dimethyl-[3-(naphthalen-1-yloxy)-3-thiophen-2-yl-propyl]-amine Oxalate

SN

CH3

CH3

O

Dimethyl-[3-(naphthalen-1-yloxy)-3-thiophen-2-yl-propyl]-amine

311.44

C19H21NOS



Stage-4:

SN

CH3

CH3

OO OH

OHO

C21H23NO5S

401.48

Dimethyl-[3-(naphthalen-1-yloxy)-3-thiophen-2-yl-propyl]-amine Oxalate

+OCl

O

C7H5ClO2

156.57

Phenyl chloro formate

+ H2O

18.00

NaOH

S

HN

CH3

OO OH

OHO

Methyl-[3-(naphthalen-1-yloxy)-3-thiophen-2-yl-propyl]-amine; compound with oxalic acid

C20H21NO5S

387.45

+

OH

Phenol

94.11

+ CH3Cl

50.49

Methyl chloride

+ CO2

Carbon dioxide

44.00

Stage-5:

S

HN

CH3

OO OH

OHO

Methyl-[3-(naphthalen-1-yloxy)-3-thiophen-2-yl-propyl]-amine; compound with oxalic acid

C20H21NO5S

387.45

+ HCl

Hydrochloric acid

36.5

Aq.NH3

Ethyl acetate

S

HN

CH3

O

HCl

O OH

OHO

Duloxetine Hydrochloride

C18H20ClNOS

333.88

Oxalic acid

90.03

+



Flow Chart:

Stage-1

3-Dimethylamino-1-thiophen-2-yl-propan-1-olL(+) Mandelic acidEthyl acetate

Ethyl acetate Rec

Stage-2 MDC RecStage-1DichloromethaneSodium carbonate

Stage-3 DMSO RecToluene Rec

Stage-21-FluoroNapthaleneOxalic acidDMSOToluene

Stage-4 Toluene Rec

Stage-3Phenyl chloroformateSodium carbonateToluene

Stage-5 Ethyl acetate Rec

Stage-4Hydrochloric acidEthyl acetate


Material Balance:

Material balance of Duloxetine Hydrochloride Stage-1

Batch Size: 200.0Kg




237.00 Stage-1 215.00

L(+) Mandelic acid 98.00 Ethyl acetate Recovery 340.00


Isomer recovery 118.50


Process residue-1.5 Distillation residue-2 (Ethyl acetate-2)





Batch Size: 200.0Kg



Stage-1 215.00 Stage-2 118.00

Dichloromethane 200.00 Dichloromethane Recovery 185.00

Sodium carbonate 5.00 Dichloromethane Loss 10.00

Sodium chloride 10.00 Cyclo hexane Recovery 361.00

Cyclo hexane 380.00 Cyclo hexane Loss 19.00


(Water-1000,Sodium carbonate-5,Sodium chloride-10)

0

Mandelic acid recovery 96.95


Process residue-0.05 Distillation residue-5 (DCM-5)

Total 1810.00 Total 1810.00


Batch Size: 200.0Kg



Stage-2 118.00 Stage-3 255.00

1-FluoroNapthalene 93.00 Toluene Recovery 945.00

Oxalic acid 58.00 Toluene Loss 50.00

Sodium hydroxide 10.00 Isopropyl alcohol Recovery 285.00

DMSO 5.00 Isopropyl alcohol Loss 15.00

TBAB 3.00 Effluent water 1020.00

Toluene 1000.00 (Water-1000,DMSO-5, TBAB-3,Sodium hydroxide-10, Toluene-2)

0

Isopropyl alcohol 300.00 Process emission 12.62

Water 1000.00 (Hydrogen Flouride-12.62) 0


Process residue-1.38 Distillation residue -3 (Toluene-3)

Total 2587.00 Total 2587.00




Batch Size: 200.0Kg



Stage-3 255.00 Stage-4 240.00

Phenyl chloroformate 100.00 Toluene Recovery 940.00

Sodium carbonate 0.60 Toluene Loss 50.00

Sodium sulfate 10.00 Ethyl acetate Recovery 1045.00

Sodium hydroxide 6.70 Ethyl acetate Loss 55.00

DMSO 2.00 Effluent water 1374.07

TEA 5.00 (Water-1288,DMSO-2, Oxalic Acid-10 ,TEA-5, Phenol-59.77, Toluene-2,sodium carbonate-0.6,sodium hydroxide-6.7)

0

Oxalic acid 10.00 Inorganic Residue 10.00

Toluene 1000.00 (Sodium sulphate-10) 0

Ethyl acetate 1100.00 Process Emission 60.02

DM. water 1300.00 (Carbon dioxide-27.94,Methyl chloride-32.06,)

0


Process residue-7.21 Distillation residue (Toluene-8)

Total 3789.30 Total 3789.30


Batch Size: 200.0Kg



Stage-4 240.00 Duloxetine Hydrochloride 200.00

Hydrochloric acid 23.00 Ethyl acetate Recovery 95.00


Methanol 4.00 Methanol Recovery 4.00

Oxalic acid Recovery 56.00


Process residue-7




LANSOPRAZOLE

Process Description

Stage-1

2, 3-Lutidine reacts with Hydrogen Peroxide and Nitric Acid in Presence of Acetic

acid to give stage-1 product.

Stage-2

Stage-1 Product reacts with 1, 1, 2- trifluoroethanol and Acetic Anhydride in

presence of Potassium Carbonate to give stage-2 product.

Stage-3

Stage-2 product undergoes chlorination with Thionyl Chloride in presence of Toluene

to give stage-3 product.

Stage-4

Stage-3 product undergoes condensation with 1H-Benzoimidazole-2-thiol in

presence of Sodium Hydroxide to give stage-4 product.

Stage-5

Stage-4 product undergoes oxidation with Hydrogen peroxide in presence of IPA to

give Lansoprazole.

Route of Synthesis:

Stage-1

2,3-Lutidine

107.15

+

H2O2

34.00

+ HNO3

63.00

+ 2 H2O

C7H9N

36.044-Nitro-2,3-Dimethyl pyridine-N-Oxide

168.15

C7H8N2O3

N+

O-

H3C

H3C

NO2

N

CH3

CH3

Hydrogen Peroxide

HO OH



Stage-2

+

4-Nitro-2,3-Dimethyl pyridine-N-Oxide

168.15

CF3CH2OH

+ K2CO3+

C4H6O3

+ + HCl

100.04 102.09

N

OCH2CF3

CH3

CH2OH

. HCl

257.64

+ KHCO3

100.12

+ KNO2

85.10

+CH3COONa

82.03

CH3COOH

C7H8N2O3

C9H11ClF3NO2

OO

OOHF

F

F

N+

O-

H3C

H3C

NO2

1,1,2-Trifluoro-ethanol Acetic anhydride 138.21

NaOH

40.00 36.46

60.05

+

[3-Methyl-4-(2,2,2-trifluoro-ethoxy)-pyridin-2-yl]-methanol

Stage-3

N

OCH2CF3

CH3

CH2OH

. HCl

257.64

+

C9H11ClF3NO2

[3-Methyl-4-(2,2,2-trifluoro-ethoxy)-pyridin-2-yl]-methanol

+

SOCl2

Thionyl chloride

118.97

N

OCH2CF3

CH3

CH2Cl

. HCl

276.08

SO2

64.06

+ HCl

36.46

C9H10Cl2F3NO

S

O

Cl

Cl

2-Chloromethyl-3-methyl-4-(2,2,2-trifluoro-ethoxy)-pyridine Hydrochloride



Stage-4

N

OCH2CF3

CH3

CH2Cl

. HCl

276.08

C9H10Cl2F3NO

2-Chloromethyl-3-methyl-4-(2,2,2-trifluoro-ethoxy)-pyridine Hydrochloride

+

N

HN

HS + 2 NaoH

80.00

150.20

N

OCH2CF3

CH3

CH2 SN

HN

+ 2 NaCl

116.88

+ 2 H2O

36.04

C7H6N2S

C16H14F3N3OS

353.36

1H-Benzoimidazole-2-thiol

2-[3-Methyl-4-(2,2,2-trifluoro-ethoxy)-pyridin-2-ylmethylthio]-1H-benzo[d]imidazole

Stage-5

N

OCH2CF3

CH3

CH2 SN

HN

+

C16H14F3N3OS

353.36

2-[3-Methyl-4-(2,2,2-trifluoro-ethoxy)-pyridin-2-ylmethylthio]-1H-benzo[d]imidazole

+

H2O2

Hydrogen peroxide

N

OCH2CF3

CH3

CH2 SN

HN

O

Lansoprazole

369.36

H2O

18.02C16H14F3N3O2S

HO OH

34.01



Flow Chart:

Stage-1

Stage-2

Stage-3

Stage-4

Stage-5

2,3-LutidineAcetic AcidHydrogen Peroxide (50%)Sulfuric AcidNitric Acid Effluent water

Stage-1Sodium HydroxidePotassium Carbonate1,1,2-Tri Fluoro EthanolMIBKAcetic AnhydrideTEBACTolueneHydrogen Chloride Activated Carbon

Stage-2Methylene DichlorideTolueneThionyl Chloride

Stage-3Sodium Hydroxide1H-Benzoimidazole-2thiol

Stage-4Isopropyl AlcoholHydrogen Peroxide (50%)CatalystChloroformAcetone

Isopropyl alcohol RecoveryAcetone recoveryEffluent water

Effluent water

Toluene recoveryMethylene Dichloride RecoveryEffluent water

MIBK RecoveryToluene RecoveryEffluent water

LANSOPRAZOLE

Material Balance:

Material Balance of Lansoprazole

Stage-1

Batch Size:500Kg

Name of the input Quantity

in Kg

Name of the out put Quantity

in Kg

2,3-Lutidine 188.00 Stage-1 280.00

Acetic Acid 46.00 Spent Sulfuric Acid 50.00

Hydrogen Peroxide (50%) 120.00 Effluent water 969.23



Sulfuric Acid 50.00 (Water-800, Generatedwater-

63.23,water from hydrogen peroxide-

60, Acetic Acid - 46)

0

Nitric Acid 111.00 Organic Residue 15.77

Water 800.00 Process residue – 15.77

Total 1315.00 Total 1315.00


Stage-2

Batch Size:500Kg


in Kg


in Kg

Stage-1 280.00 Stage-2 405.00

Sodium Hydroxide 67.00 MIBK Recovery 140.00

Potassium Carbonate 230.00 MIBK Loss 5.00

1,1,2-Tri Fluoro Ethanol 167.00 Toluene Recovery 380.00

MIBK 150.00 Toluene Loss 10.00

Acetic Anhydride 170.00 Effluent Water 1041.59

TEBAC 1.00 (Water-800, Sodium Acetate-136.59,

Acetic Acid-100,Toluene-5)

0

Toluene 400.00 Inorganic solid waste 308.70

Hydrogen Chloride 61.00 (Potassium Nitrite-141.70, Potassium

Bicarbonate-167)

0

Activated Carbon 5.00 Spent Carbon 5.00

Water 800.00 Organic Residue 35.71

Process Residue-25.71

Distillation Residue-10

(MIBK-5,Toluene-5)

Total 2331.00 Total 2331.00


Stage-3

Batch Size:500Kg


in Kg


in Kg

Stage-2 405.00 Stage-3 415.00

Methylene Dichloride 400.00 Toluene Recovery 475.00

Toluene 500.00 Toluene Loss 15

Thionyl Chloride 180.00 Methylene Dichloride Recovery 380.00

Methylene Dichloride Loss 12.00

Process Emissions 152.68

(Sulfur Dioxide-97.50,Hydrogen

Chloride-55.18)

0




Process residue- 17.32

Distillation Residue-18

(Toluene-10,

Methylene Dichloride -8)

Total 1485.00 Total 1485.00


Stage-4

Batch Size:500Kg


in Kg


in Kg

Stage-3 415.00 Stage-4 505.00

Sodium Hydroxide 121.00 Effluent Water 829.88

1H-Benzoimidazole-2thiol 226.00 (Water-600, Generated Water-

54.18,Sodium Chloride-175.70)

0

Water 600.00 Organic Residue 27.12

(Process Residue-27.12)

Total 1362.00 Total 1362.00


Stage-5

Batch Size:500Kg


in Kg


in Kg

Stage-4 505.00 Lansoprazole 500.00

Isopropyl Alcohol 250.00 Isopropyl Alcohol Recovery 238.00

Hydrogen Peroxide (50%) 98.00 Isopropyl Alcohol Loss 5.00

Catalyst 1.00 Chloroform Recovery 384.00

Chloroform 400.00 Chloroform Loss 12.00

Acetone 150.00 Acetone Recovery 143.00

Water 600.00 Acetone Loss 3.00

Effluent Water 674.75

(Water-600, Generated Water-

25.75, Water from Hydrogen

peroxide-49)

0

Catalyst Reuse 1.00



Distillation residue-15

(IPA-7, Chloroform-4,Acetone-4)

Total 2004.00 Total 2004.00



LOPINAVIR

Process Description

Stage-1

Step-A

(R)-2-amino-3-phenyl propanoic acid reacts with benzyl chloride ,Potassium

carbonate in presence of Ethanol to give Stage-A product.

Step-B

Stage-A Product reacts with Acetonitrile, Sodium amide and citric acid monohydrate

in presence of MTBE to give Stage-1 product.

Stage-2

Satge-1 reacts with Benzyl magnesium chloride in presence of THF, MTBE to give

Stage-2 product.

Stage-3

Step-A

Stage-2 product reacts with sodium borohydride in presence of Methane sulphonic

acid, TEA and 1, 2-DME to give step-A as product.

Step-B

Valina reacts with Methyl chloro formate and Acrylonitrile to give Stage-3B as

product.

Step-C

Stage-3C Product undergoes Hydrogenation by using Raney nickel as catalyst and

methanol to give Stage-3C product.

Step-D

(2S)- (1-Tetra hydro pyramid-2-one)-3-methyl butanoic acid reacts with Imidazole in

presence of THF to give Step-D product.

Step-E

Step-A reacts with Step-D in presence of Ethyl acetate to give Step-E product.

Step-F

Step-E reacts with Ammonium formate in presence of Palladium carbon and

Methanol to give Step-F product.

Step-G

Step-F product reacts with L-Pyro glutamic acid in presence of DMF, Ethyl acetate to

give (2S, 3S, 5S)-2-Amino-3-hydroxy-5-(1-tetra hydro pyrmid-2-onyl)-3-methyl

butanoyl) amino-1, 6-diphenyl hexane-S-pyro glutamate (THP).



Stage-4

N-(4-Amino-1-benzyl-3-hydroxy-5-phenyl-pentyl)-3-methyl-2-(2-oxo-

tetrahydropyrimidin-1-yl)-butyramide (S)-5-oxo-pyrrolidine-2-carboxylate reacts with

2,6-Dimethyl phenoxy acetyl chloride and sodium bicarbonate in the presence of

Ethyl acetate to give stage-4 as product.

Stage-5

Stage-4 undergoes purification with ethanol to give Lopinavir (pure).

Route of Synthesis:

Stage-1

Step-A

(R)-2-amino-3-phenyl propanoic acid

O

OH

H2N

+

Benzyl Chloride

Cl

(R) -benzyl 2-(dibenzyl amino)-3-phenyl propanoate

O

O

N

3 + K2CO3

Potassium Carbonate

C9H11NO2

165.19

C7H7Cl

3X126.58=379.74138.21

+ 2 KCl + +

C30H29NO2

435.56

2X74.55=149.10

Ethanol

Potassium Chloride

HCl

36.46

Hydrogen Chloride

CO2

44.01

+ H2O

18.02Carbon dioxide



Step-B

Monosodium citrate

(R) -benzyl 2-(dibenzyl amino)-3-phenyl propanoate

C30H29NO2

435.56

+ CH3CN + NaNH2 +

C6H10O8

Acetonitrile Sodium Amide Citric Acid Monohydrate

41.05 39.01 210.14

MTBE

OH

1-Imino-4-(N,N-dibenzylamino)5-phenyl-3-oxo-pent-1-ene

C25H24N2O

368.47

+ + + NH3

Benzyl Alcohol Ammonia

C7H8O

108.14 214.11

C6H7O7Na

OO

N

C

O

N

NH

HO

OOH

O OH

O

HOH2O

Na+

HO

OO-

O OH

O

HO + H2O

17.03

18.0



Stage-2

1-Imino-4-(N,N dibenzylamino)-5-phenyl-3-oxo-pent-1-ene

C

O

N

NH

C25H24N2O

368.47

Benzyl Magnesium Chloride

Mg

Cl

+

Citric Acid monohydrate

(R,Z)-5-amino-2-(dibenzyl amino)-1,6-diphenyl hex-4-en-3-one

ON

NH2

Magnesium Chloride

+ + NaCl

58.44

C7H7MgCl

150.89210.14

C32H32N2O

460.61

+MgCl2

95.21

+

C6H7O7Na

Monosodium Citrate

+ H2O

214.11

18.02

THF/MTBE

HO

O

OH

O OH

O

HO

. H2O

Sodium Chloride

C6H10O8

Na+

HO

O

O-

O OH

O

HO



Stage-3

Step-A


ON

NH2

C32H32N2O

460.61

(2R)-5-amino-2-(dibenzyl amino)-1,6-diphenyl hexane-3-ol

OHN

NH2

+ NaBH4 + 3H2O

37.83

54.06

C32H36N2O

464.64

+ H3BO3

61.83

MSA

TEA/1,2 DME

sodium Borohydride

+HCl

36.46

Hydrochloric acid

Boric acid

+ NaCl

58.44

Sodium chloride

2 H2

4.04

+



Step-B

HO

O

NH2

CH3H3C

valina

C5H11NO2

117.15

+

Methylchloroformate

O

OClCH3

C2H3ClO2

94.50

+

Acrylonitrile

CH2

N

C3H3N

53.06

N-(2-Cyanoethyl)-N-(methoxycarbonyl)-L-valine

CN

N OCH3

OH3C CH3

HO

O

C10H16N2O4

228.25

+ HCl

Hydrochloric acid

36.5

Step-C

N-(2-Cyanoethyl)-N-(methoxycarbonyl)-L-valine

CN

N OCH3

OH3C CH3

HO

O

C10H16N2O4

228.25

Raney Ni

Methanol,NaOH

N NH

OH3C CH3

HO

O

3-Methyl-2-(2-oxo-tetrahydro-pyrimidin-1-yl)-butyric acid

C9H16N2O3

200.23

+ 2H2

4.00

+CH3OH

32.04

Metahnol



Step-D

N

N

(2S)-(1-Tetrahydropyramid-2-one)-3-methylbutanoic acid

N

NH

O

OH

O

Imidazole

+

N

NH

O

O

C9H16N2O3

C3H4N2 C12H18N4O2

200.2368.07

250.30

+H2O

18.02

N

HN

1-[1-(Imidazole-1-carbonyl)-2-methyl-propyl]-tetrahydro-pyrimidin-2-one

THF

Step-E

N NN NH

O

O

1-[1-(4,5-Dihydro-imidazole-1-carbonyl)-2-methyl-propyl]-tetrahydro-pyrimidin-2-one

OHN

NH

N NH

N NH

O

O

Imidazole

OHN

NH2

5-Amino-2-dibenzylamino-1,6-diphenyl-hexan-3-ol

+

N-(1-Benzyl-4-dibenzylamino-3-hydroxy-5-phenyl-pentyl)-3-methyl-2-(2-oxo-tetrahydro

-pyrimidin-1-yl)-butyramide

C41H50N4O3

+

646.86

C3H4N2

68.08

C32H36N2O

464.64

Ethyl acetate

Water

C12H18N4O2

250.30



Step-F

OHN

NH

N NH

O

O

N-(1-Benzyl-4-dibenzylamino-3-hydroxy-5-phenyl-pentyl)-3-methyl-2-(2-oxo-tetrahydro

-pyrimidin-1-yl)-butyramide

C41H50N4O3

646.86

+

Pd/C

OH

H2N

NH

N NH

O

O

N-(4-Amino-1-benzyl-3-hydroxy-5-phenyl-pentyl)-3-methyl-2-(2-oxo-tetrahydro-pyrimidin-1-yl)-

butyramide

+

Ammonium formate

63.06

C27H38N4O3

466.62

Toluene

C7H8

2 X 92.14=184.28

+ NH3

Ammonia

17.03

+

Carbondioxide

44.01

MeoHNH4

+

O-O

CH5NO2

CO2

+ H2

2.02

2



Step-G

OH

H2N

NH

N NH

O

O

N-(4-Amino-1-benzyl-3-hydroxy-5-phenyl-pentyl)-3-methyl-2-(2-oxo-tetrahydro-pyrimidin-1-yl)-

butyramide

C27H38N4O3

466.62

+

L-Pyroglutamic acid

HN

O

O

OH

C5H7NO3

129.11

DMF

Ethyl acetate

OH

H2N

NH

N NH

O

O

HN

O

O

OH

(2S, 3S, 5S)-2-Amino-3-hydroxy-5-(1-tetra hydro pyrmid-2-onyl)-3-methyl butanoyl) amino-1, 6

-diphenyl hexane-S-pyro glutamate (THP)

C32H45N5O6

595.73



Stage-4

H2N

OH

NH

N

O

NH

O

NH

O

H

COOH

C32H45N5O6

595.72

+

CH3

CH3

O

HN

O

NH

OH

N

H3C CH3

O

NH

O

2,6-Dimethyl phenoxy acetyl chloride

O

CH3

CH3

O

Cl

C10H11ClO2

198.64

+

SodiumCarbonate

NaHCO3

84.00

C37H48N4O5

628.80

+NH

H

COOHO

5-Oxo-pyrrolidine-2-carboxylic acid

C5H7NO3

129.11

+ NaCl

+ H2O + CO2

Sodium chloride

58.44

18.00 44.00

Ethyl acetate

N-{1-Benzyl-4-[2-(2,6-dimethyl-phenoxy)-acetylamino]-3-hydroxy-5-phenyl-pentyl}-3-methyl-2-(2-oxo-tetrahydro-

pyrimidin-1-yl)-butyramide (Lopinavir Crude)

N-(4-Amino-1-benzyl-3-hydroxy-5-phenyl-pentyl)-3-methyl-2-(2-oxo-tetrahydro-pyrimidin-1-yl)-butyramide;

compound with 5-oxo-pyrrolidine-2-carboxylic acid



Stage-5

CH3

CH3

O

HN

O

NH

OH

N

H3C CH3

O

NH

O

N-{1-Benzyl-4-[2-(2,6-dimethyl-phenoxy)-acetylamino]-3-hydroxy-5-phenyl-pentyl}-3-methyl-2-(2-oxo-tetrahydro-

pyrimidin-1-yl)-butyramide(Lopinavir Crude)

C37H48N4O5

628.80

CH3

CH3

O

HN

O

NH

OH

N

H3C CH3

O

NH

O

Ethanol

C37H48N4O5

628.80

Lopinavir (pure)



Flow Chart:

Stage-1

Stage-2

Stage-3

Stage-4

LOPINAVIR

(R)-2-amino-3-phenyl propanoic acidPotassium carbonateBenzyl chlorideEthanoln-HeptaneMethanolSodamideAcetonitrileCitric acid monohydrateMTBE

MTBE RecoveryEthanol RecoveryElluent water

MTBE RecoveryTHF Recoveryeffluent water

Methanol RecoveryEthyl acetaet RecoveryEffluent water

Acetone RecoveryEthyl acetate RecoveryEffluent water

Stage-5 Spent Carbon

Benzyl magnesium chlorideCitric acid monohydrateTHFSodium chlorideEthanolMTBESodium Boro hydrideMethane sulphonic acidImidazoleTPATHFEthyl acetateAmmonium formateMethanolPalladium carbon

2,6-Dimethyl phenoxy acetyl chloride (DPC)Ethyl acetateSodium bicarbonate (10%)Sodium chloride (10%)Sodium sulphateAcetone

EthanolActivated carbonHyflow



Material Balance:

Material Balance of Lopinavir Stage-1

Batch Size: 250Kg



(R)-2-amino-3-phenyl propanoic acid

103.00 Stage-1 210.00

Potassium carbonate 86.00 n-Heptane Recovery 238.00

Benzyl chloride 237.00 n-Heptane Loss 12.00

Ethanol 500.00 MTBE Recovery 475.00

n-Heptane 250.00 MTBE Loss 25.00


Sodamide 23.00 Methanol Loss 10.00

Acetonitrile 24.35 Ethanol Recovery 475.00

Citric acid monohydrate 124.85 Ethanol Loss 15.00

MTBE 500.00 Effluent water 452.00

Water 250.00 (Water-250,Generated Water-10.62, Benzyl Alcohol-64.23, Monosodium citrate-127.15)

0


(Potassium chloride-92.90) 0


(Carbon dioxide-27.39, Hydrogen chloride-22.66,Ammonia-10.10)

0


Orgnanic Impurities-33.15 Distillation residue-20 (Methanol-10,Ethanol-10)

Total 2498.20 Total 2498.20


Batch Size: 250Kg



Stage-1 210.00 Stage-2 252.00

Benzyl magnesium chloride 85.90 Ethanol Recovery 380.00

Citric acid monohydrate 119.70 Ethanol Loss 10.00

THF 400.00 MTBE Recovery 570.00

Sodium chloride 33.20 MTBE Loss 30.00

Ethanol 400.00 THF Recovery 380.00

MTBE 600.00 THF Loss 10.00


(Water-300, Generated water-10.08, Monosodium citrate-122.01, Magnesium chloride-54.18)

0




Process residue-10.53 Distillation residue-20 (Ethanol-10,THF-10)

Total 2148.80 Total 2148.80


Batch Size: 250Kg



Stage-2 252.00 (2S, 3S, 5S)-2-Amino-3-hydroxy-5-(1-tetra hydro pyrmid-2-onyl)-3-methyl butanoyl) amino-1,6-diphenyl hexane-S-pyro glutamate (THP)

257.00

Sodium Boro hydride 20.65 1,2-Dimethoxy ethane Recovery 285.00

Methane sulphonic acid 7.00 1,2-Dimethoxy ethane Loss 15.00

Triethyl amine 96.00 MTBE Recovery 238.00

1,2-Dimethoxy ethane 300.00 MTBE Loss 12.00

MTBE 250.00 THF Recovery 475.00

Ammonium chloride 200.00 THF Loss 15.00

Imidazole 39.65 IPA Recovery 285.00

TPA 55.00 IPA Loss 15.000

THF 500.00 Ethyl acetate Recovery 760.00


Ammonium formate 29.48 Methanol Recovery 475.00

Methanol 500.00 Methanol Loss 15.00

Palladium carbon 20.60 DMF Recovery 285.00

L-Pyro glutamic acid 57.96 DMF Loss 15.00

DMF 300.00 MDC Recovery 570.00

Hydrochloric acid 20.00 MDC Loss 12.00

IPA 300.00 Dimethyl Acetamide recovery 152.00

Dimethyl acetamide 160.00 Dimethyl Acetamide Loss 8.00

MDC 600.00 Triethyl amine Reuse 96.00

Valina 75.00 Effluent water 692.91

Methyl chloro formate 60.45 (Water-470.52,Generated water-10.42,Boric acid-33.75, Sodium Chloride-31.75 Methane sulphonic acid-7,imidazole-35.47,Ethyl acetate-8,TEA-96)

0

Acrylonitrile 34.00 Spent Catalysts 25.60

Hydrogen gas 3.29 (Palladium carbon Recovered-20.60, Raney Nickel Recovered-5.00)

0

Raney Nickel 5.00 (Toluene Recovery + Methanol recovery) Mixed Solvent

106.25

Water 500.00 Process Emissions 71.99

(Hydrogen-20.1,Carbondioxide-20.67,Ammonia-7.90,Hydrochloric acid-23.32 )

0

Inorganic Solid Waste 200.00



(Ammonium Chloride) 0


Process residue-34.33 Distillation residue-46 (Methanol-10,Ethyl acetate-8,THF-10,MDC-18)

Total 5186.08 Total 5186.08


Batch Size: 250.0 Kg



THP(Lopinavir Intermediate) 257.00 Stage-4 260.00

2,6-Dimethyl phenoxy acetyl chloride (DPC)

85.50 Ethyl acetate Recovery 760.00


Sodium bicarbonate (10%) 362.50 Acetone Recovery 473.00

Sodium chloride (10%) 100.00 Acetone Loss 25.00

Sodium sulphate 20.00 Effluent Water 1004.36

Acetone 500.00 (Water-500,generated water-7.71,Sodium chloride-25.20 water from Sodium bicarbonate-326.25,water from Sodium chloride-90, Pyroglutamic acid-55.20)

0

Activated carbon 2.50 Spent Carbon 2.50

Water 500.00 Inorganic Solid Waste 20.00

(Sodium Sulfate) 0


(Carbon dioxide-18.76) 0



Distillation residue-2 (Acetone-2)

Total 2627.50 Total 2627.50


Batch Size: 250.0 Kg



Stage-4 260.00 Lopinavir(pure) 250.00

Ethanol 500.00 Ethanol Recovery 475.00

Activated carbon 3.50 Ethanol Loss 20.00

Hyflow 5.00 Spent carbon & Hyflow 8.50

Water 500.00 Effluent Water 500.00

(Water-500) 0




Process residue-10

Distillation residue-5 (Ethanol-5)

Total 1268.50 Total 1268.50

MOXIFLOXACIN HYDROCHLORIDE


Stage-1

Moxifloxacin Q-acid is reacted with 2, 8-Diazobicycloc (4.3.0) nonane in presence of

Triethylamine in Acetone and Dimethylformamide to give stage-1 Product.

Stage-2

Stage-1 Product reacts with Hydrochloric acid in presence of Methanol to give

Moxifloxacin Hydrochloride.

Route of Synthesis:

Stage-1

NF

F

OCH3

O

COOH

+

NH

NH

H

H

+

(C2H5)3N

Acetone

N

F

OCH3

O

COOH

NH

N

H

H

Moxifloxacin Q-acid

C14H11F2NO4

295.24

2,8-Diazobicyclo(4.3.0)nonane

C7H14N2

126.20

Triethylamine

101.19

Moxifloxacin Base

C21H24FN3O4

401.43

+

(C2H5)3N.HF

Triethyl amine Hydrofluoride

121.20

N HF.

N



Stage-2:

N

F

OCH3

COOH

NH

N

H

H

Moxifloxacin Base

C21H24FN3O4

401.43

+ HCl

Hydrochloric acid

36.5

Methanol

N

F

OCH3

O

COOH

NH

N

H

H

Moxifloxacin Hydrochloride

HCl

C21H25FClN3O4

437.89

O

Flow Chart:

Moxifloxacin Q-Acid2,8-Diazobicyclo(4.3.0)nonaneTriethylamineAcetoneDimethylformamide

Stage-1 Acetone RecDMF Rec

Stage-2

Moxifloxacin BaseHydrochloric acidMethanolEDTA

Methanol Rec

MOXIFLOXACIN HDYROCHLORIDE



Material Balance:

Material Balance of Moxifloxacin Hydrochloride Stage-1

Batch Size:100Kg



Moxifloxacin Q-Acid 80.00 Stage-1 97.00

2,8-Diazobicyclo(4.3.0) nonane 34.50 Acetone Recovery 190.00

Triethylamine 27.35 Acetone Loss 10.00

Acetone 200.00 Dimethylformamide Recovery 95.00

Dimethylformamide 100.00 Dimethylformamide Loss 5.00


Process residue-12.05 (Triethyl amine hydro fluoride-32.80)


Material Balance of Moxifloxacin Hydrochloride

Stage-2

Batch Size: 100Kg


in Kg


in Kg

Moxifloxacin Base 97.00 Moxifloxacin Hydrochloride 100.00

Hydrochloric acid 10.00 Methanol Recovery 475.00


EDTA 1.00 Effluent Water 1504.00

Activated Carbon 5.00 (Water-1500,EDTA-1,Methanol-3) 0

Water 1500.00 Spent Carbon 5.00


Process residue-4

Total 2113.00 Total 2113.00

NEBIVOLOL HYDROCHLORIDE


Stage-1:

6-Fluoro-2-oxiranyl-chroman undergoes column separation to give Stage-1 product. Stage-2:

Stage-1 reacts with Benzyl amine in presence of IPA to give Stage-2 product.

Stage-3:

Stage-2 reacts with 6-Fluoro-2-o-Oxiranyl-chroman in presence of Methanol to give

Stage-3 product.



Stage-4:

Stage-3 reacts with Hydrochloric acid in presence of Pd/C to give Nebivolol

Hydrochloride.

Route of synthesis:

Stage-1:

O O

F

O O

F

6-Fluoro-2-oxiranyl-chroman

C11H11FO2

194.20

Column seperation


C11H11FO2

388.40

O O

F


C11H11FO2

194.20

+2

Stage-2:

O O

F


C11H11FO2

194.20

NH2

Benzylamine

C7H9N

107.15

+IPA

2-Benzylamino-1-(6-fluoro-chroman-2-yl)-ethanol

C18H20FNO2

301.36

O

HN

F

OH

Stage-3:

2-Benzylamino-1-(6-fluoro-chroman-2-yl)-ethanol

C18H20FNO2

O

F

O


C11H11FO2

194.20

O

HN

O

N O

F

OH

OH

F

495.56

C29H31F2NO4

+Methanol

301.36

F

OH

PhH2C

2-{Benzyl-[2-(6-fluoro-chroman-2-yl)-2-hydroxy-ethyl]-amino}-1

-(6-fluoro-chroman-2-yl)-ethanol



Stage-4:

O

N O

F

OH

OH

F

2-{Benzyl-[2-(6-fluoro-chroman-2-yl)-2-hydroxy-ethyl]-amino}-1-(6-fluoro-chroman-2-yl)-ethanol

495.56

C29H31F2NO4

HCl

96.56

+

O

HN O

F

OH

OH

F

HCl

C22H26ClF2NO4

441.90

Nebivolol Hydrochloride

Isopropyl alcohol Hydrochloride

CH3

CH3

HO

CH3

CH3

HO+

Isopropyl alcohol

60.10

Methanol

+ H2

Hydrogen

2.00

+

Toluene

CH3

92.14

Pd/C



Flow chart:

6-Fluoro-2-oxiranyl-chromanSilica gelEthyl acetate

Stage-2Benzyl amineIPA

Stage-36-Fluro-2-oxiranyl-chromanMethanol

Stage-4Hydrochloric acidPd/Carbon


Stage-1

Stage-2

Stage-3

Stage-4

IPA Rec

Methanol RecEffluent water

Effluent water

Ethyl acetate RecoveryEffluent water

Material Balance:

Material Balance of Nebivolol HCl

Stage-1 Batch Size: 200.00Kgs



6-Fluoro-2-oxiranyl-chroman 198.00 Stage-1 96.00

Silicagel 20.00 Hexane Recovery 285.00

Hexane 300.00 Hexane Loss 15.00

Ethyl acetate 300.00 Ethyl acetate Recovery 283.00

Ethyl acetate Loss 15.00

Inorganic solid waste (Silicagel-20)

20.00


Process residue- 102 (6-Fluoro-2-Oxiranyl-chroman-99) Distillation residue (Ethyl acetate-2)





Stage-2 Batch Size:200.00 Kgs



Stage-1 96.00 Stage-2 144.00

Benzylamine 52.90 IPA Recovery 283.00

IPA 300.00 IPA Loss 15.00


Process residue-4.9 Distillation residue (IPA-2)


Material Balance of Nebivolol HCl Stage-3

Batch Size:200.00 Kgs



Stage-2 144.00 Stage-3 230.00

Stage-1 96.00 Methanol Recovery 283.00


DIPE 300.00 DIPE Recovery 285.00

Acetonitrile 250.00 DIPE Loss 15.00

Acetonitrile Recovery 237.50

Acetonitrile Loss 12.50


Process residue-10 Distillation residue-2 Methanol-2)

0

Total 1090.00 Total 1090.00


Stage-4 Batch Size: 200.00 Kgs



Stage-3 230.00 Nebivolol Hydrochloride 200.00

IPA.HCl 44.62 (Methanol + IPA + Toluene ) mixed Solvent

355.38

Hydrogen 0.92 Methanol Loss 15.00

Palladium Catalyst 2.00 Spent hyflow 7.66

Hyflow 0.50 Organic Residue-7.66 (Process residue-7.66)

Methanol 300.00




RITONAVIR

Process description:

Stage-1

(R,Z)-5-Amino-2-(dibenzyl amino)-1,6-diphenyl hex-4-en-3-one reacts with sodium

borohydride in presence of methanol , HCl and water to give (2R)-5-amino-2-

(dibenzyl amino)-1,6-diphenyl hexane-3-ol.

Stage-2

Stage-1 product reacts with di-tert-butyl oxydiformate in presence of MTBE,

Potassium carbonate and HCl to give stage-2 product.

Stage-3

Stage-2 product reacts with ammonium farmate in presence of Methanol to give

Stage-3 Product.

Stage-4

Stage-3 Product reacts with succinic acid in presence of IPA, Acetic acid and sodium

hydroxide to give stage-4 product.

Stage-5

Step-A

Thiourea reacts with 2-chloro-3-oxo-propionic acid ethyl ester in presence of isoamyl

nitrite to give stage-5 product.

Step-B

Step-A product reacts with sodium borohydride in presence of methanol and HCl to

give step-B product.

Step-C

Step-B product reacts with hydrogen in presence of methanol and Pd/C to give step-

c product of stage-5.

Stage-6

Stage-5 product reacts with 4-Nitro phenyl chloro formate in presence of pyridine

and sodium bicarbonate to give stage-6 product.

Stage-7

Stage-6 product undergoes condensation with stage-4 product in presence of

toluene and methanol to give stage-7 product.

Stage-8

Isobutyramide reacts with phosphorus penta sulphide in presence of toluene and

sodium hydroxide to give stage-8 product.

Stage-9

Stage-8 product reacts with 1,3-dichloro acetone & monomethyl amine in presence

of sodium hydroxide and toluene to give stage-9 product.

Stage-10

Stage-9 product reacts with (S)-methyl-3-methyl-2-((4-Nitrophenoxy)carbonyl

amino)butanoate in presence of LiOH and methanol to give stage-10 product.

Stage-11

N-((N-methyl-N-((2-isopropyl-4-thiazolyl)methyl)amino)carbonyl)-L-valine reacts with

(1-Benzyl-4-tert-butoxycarbonylamino-2-hydroxy-5-phenyl-pentyl)-carbamic acid

thiazol-5-ylmethyl ester of THF to give Ritonavir product.



Stage-12

Ritonavir undergoes recrystallisation in n-Heptane to give Ritonavir product.

Route of Synthesis:

Stage-1


ON

NH2

C32H32N2O

460.61


OHN

NH2

+ NaBH4 + 3H2O

37.83

54.06

C32H36N2O

464.64

+ H3BO3

61.83

MSA

TEA/1,2 DME

sodium Borohydride

+HCl

36.46

Hydrochloric acid

Boric acid

+ NaCl

58.44

Sodium chloride

2 H2

4.04

+



Stage-2


OHN

NH2

C32H36N2O

464.64

OHN

HN C

O

O

CH3

CH3

CH3

(1-Benzyl-4-dibenzylamino-3-hydroxy-5-phenyl-pentyl)-carbamic acid tert-butyl ester

O

O

KO

H3CCH3

CH3

Di Potassium tert-butylcarbonate

Di-tert-butyl oxydiformate

O

O

O

O

O+

+ K2CO3

MTBE

C10H18O5

218.25

138.21

+ + CO2 + KCl

C37H44N2O3

564.76

C5H9KO3

156.22

44.01 74.55

Water+ HCl

36.46

+ H2O

18.02



Stage-3

OHN

HN C

O

O

CH3CH3

CH3

(1-Benzyl-4-dibenzylamino-3-hydroxy-5-phenyl-pentyl)-carbamic

acid tert-butyl ester

C37H44N2O3

564.76

OHH2N

HN C

O

O

CH3CH3

CH3

(4-Amino-1-benzyl-3-hydroxy-5-phenyl-pentyl)-carbamic acid

tert-butyl ester

+

CH5NO2

Ammonium formate

+ + + NH3

Toluene

63.06

C23H32N2O3

384.51

2X92.14=184.28

44.0117.03

Methanol

CO2

CH3

OH4NO + H2

2.02

Carbondioxide Ammonia

C7H8



Stage-4

OHH2N

HN C

O

O

CH3CH3

CH3

(4-Amino-1-benzyl-3-hydroxy-5-phenyl-pentyl)-carbamic acid

tert-butyl ester

C23H32N2O3

384.51

Succinic Acid

O

OH

O

HO

+ + CH3COOH + NaOH

C4H6O4

118.09X0.5=59.045

60.05

40.0

OH

H2N

HN C

O

O

CH3CH3

CH3O

OH

O

HO0.5

(4-Amino-1-benzyl-3-hydroxy-5-phenyl-pentyl)-carbamic acid tert-butyl ester hemi succinic acid

C25H35N2O5

443.56

+ CH3COONa + H2O

82.0318.02

IPA,DMA

0.5

Acetic acid

Sodium acetate

Stage-5

(5HMT)

Step-A

H2N NH2

S

CH4N2S

76.12

+

OH

OO

C2H5

C5H7ClO3

150.56

Isoamyl nitrite SN

C2H5O2C

Cl

2-Chloro-3-oxo-propionic acid ethyl ester

Thiourea

NH2

2-Amino-thiazole-5-carboxylic acid ethyl ester

C6H8N2O2S

172.20

+ H2O

36.46

+ HCl

18.02

Hydrogen Chloride



Step-B

MethanolS

N

C2H5O2C

NH2

2-Amino-thiazole-5-carboxylic acid ethyl ester

C6H8N2O2S

172.20

+

3H2O

+ NaCl

NaBH4+

37.83

SN

NH2

OH

(2-Amino-thiazol-5-yl)-methanol

+ HCl

36.46

C4H6N2OS

130.17

58.44

H3BO3

61.83

+

+ C2H5OH

46.07

54.05

+ 2 H2

4.03

Sodium Borohydride Hydrochloric acid

Boric acid Sodium chloride Ethanol

Step-C

+S

N

NH2

OH

(2-Amino-thiazol-5-yl)-methanol

C4H6N2OS

130.17

H2

2.02

Pd/C,Methanol

C4H5NOS

115.15

5-Hydroxymethylthiazole(5HMT)

S

NHO

+ NH3

17.03

Ammonia



Stage-6

S

NHO

5-Hydroxymethyl thiazole

C4H5NOS

115.15

+

NO2

O C

O

Cl

4-Nitro phenyl chloro formate

C7H4O4ClN

201.56

+ NaHCO3

84.01

Pyridine

NO2

O C

O

OS

N

Carbonic acid,4-Nitrophenyl-5-thiazolyl methyl ester

C11H8O5N2S

280.26

+ NaCl +H2O

+ CO2

18.02

44.058.44

Sodium Bicarbonate

Carbon dioxideSodium chloride

Stage-7

NO2

O CO

OS

N

Carbonic acid,4-Nitrophenyl-5-thiazolyl methyl ester

C11H8O5N2S

280.26

+

OHH2N

HN C

OO

CH3CH3CH3 O

OHO

HO1/2

(4-Amino-1-benzyl-3-hydroxy-5-phenyl-pentyl)-carbamic acid tert-butyl ester

hemi succinic acid

C25H35N2O5

443.55

NO2

OH

O

SN

OHHN

HN C

O

OCH3CH3

CH3O

+ +

O

OHO

HO1/2

59.04

Hemisuccinic acid4-Nitro-phenol

C6H5NO3

139.11

(1-Benzyl-4-tert-butoxycarbonylamino-2-hydroxy-5-phenyl-pentyl)-carbamic acid thiazol-5-ylmethyl ester

C28H35N3O5S

525.66

C2H3O2



Stage-8

Isobutyramide

H3C

H3C O

NH2 + 1/2 P4S105

+ 6 NaOHH3C

H3C S

NH2

Thioisobutyramide

5

Phosphorus penta sulphideC4H9NO

5 X 87.12 = 435.6 1/2 X 444.55 = 222.27

6X40=240

C4H9NS

5X103.19=515.95

+ 2 Na3PO4 + 3 H2O

2X163.94 = 327.88

Sodium Phosphate 3X18=54

Stage-9

H3C

H3C S

NH2

Thioisobutyramide

C4H9NS

103.19

+

1,3-dichloro acetone

O

Cl Cl

C3H4OCl2

126.97

+ CH3NH2

Monomethyl Amine

+ 3 NaOH

31.06 3X40=120.0

1-(2-Isopropylthiazol-4-yl)-N-methyl methanamine

HN

H3C

S

N

CH3

CH3

C8H14N2S

170.28

+ 3 NaCl +4 H2O

175.33

72.06

+ NH4Cl

53.49

+NH3

17.03

Ammonium Chloride

Sodium Hydroxide

Sodium Chloride

Ammonia



Stage-10

1-(2-Isopropylthiazol-4-yl)-N-methyl methanamine

HN

H3C

S

N

CH3

CH3

C8H14N2S

170.28

(S)- methyl-3-methyl-2-((4-Nitrophenoxy)carbonyl amino)

butanoate

OO

HN

OO

N+

O

-O

+

(S)-2-(3-((2-Isopropylthiazol-4-yl)methyl)-3-methylureido)-3-methylbutanoic acid

NH

O

N

H3C

S

NH3C

CH3

+

C13H16N2O6

296.28

23.95

4-Nitro-phenol

O2N OH+ + LiCl + CH3OH

C14H23N3O3S

313.42

C6H5NO3

139.1

42.39 32.04

LiOH + HCl

36.46

H3C CH3

OH

O



Stage-11

O

SN

OHHN

HN C

O

O

CH3CH3

CH3O

(1-Benzyl-4-tert-butoxycarbonylamino-2-hydroxy-5-phenyl-pentyl)-carbamic acid

Thiazol-5-ylmethyl ester

C28H35N3O5S

525.66

N-((N-methyl-N-((2-isopropyl-4-thiazolyl)methyl)

amino)carbonyl)-L-valine

HN

O

HOO

NS

N

NH

O

O

NH

ONH

N

O

SN

HO

SN

+

Ritanovir

C37H48N6O5S2

720.94

+

C14H23N3O3S

313.42

THF

Tert butanol

OH

C4H10O

74.12

+ CO2

44.0

Stage-12

NH

O

O

NH

ONH

N

O

SN

HO

SN

Ritanovir crude

C37H48N6O5S2

720.94

n-Heptane

NH

O

O

NH

ONH

N

O

SN

HO

SN

Ritanovir Pure

C37H48N6O5S2

720.94



Flow chart:

Stage-1

Stage-2

Stage-3

Stage-4

(R,Z)-5-amino-2-(dibenzyl amino) -1,6-diphenyl hex-4-en-3-oneSodium Boro HydrideHydrochloric AcidMethanol

Methanol Recovery

Stage-1Di -tert-Butyl oxydiformatePotassium carbonateMTBE Methanol

Methanol RecoveryMTBE Recovery

Stage-2Ammonium Formate Methanol Methanol Recovery

Stage-3Succinic acidAcetic acidSodium hydroxideIPADMA

IPA RecoveryDMA Recovery

Stage-6

Stage-54-nitro phenyl chloro formateSodium bi carbonatePyridine Ethyl acetateToluene

Toluene RecoveryEthyl aceate Recovery

Stage-5

Thiourea 2-chloro-3-oxo-propionicacid ethyl ester Sodium boro hydride Hydrochloric acid HydrogenIso amyl nitrite Methanol Palladium on Carbon

Methanol Recovery Iso amyl ntrite Recovery



Stage-7

Stage-8

Stage-9

Stage-10

Stage-6Stage-4Methanol Toluene

Toluene RecoveryMethanol Recovery

Iso butyramidePhosphorus pentasulfideSodium hydroxideToluene

Toluene Recovery

Stage-81,3-Dichloro acetoneMono methyl amine Sodium hydroxideAmmonium chlorideToluene

Toluene Recovery

Stage-9(S)- methyl-3-methyl-2- ((4-Nitrophenoxy) carbonyl amino) butanoateLithium hydroxide Hydrochloric acidMethanol

Methanol Recovery

Stage-11Stage-10Stage-7THF Methanol

Methanol RecoveryTHF Recovery

Stage-12

Stage-11n-Heptane Activated carbon hyflow

n-Heptane Recovery

Ritonavir

Material Balance

Material Balance Ritonavir Stage-1

Batch Size:250.0 Kg



(R,Z)-5-amino-2-(dibenzyl amino) -1,6-diphenyl hex-4-en-3-one

238.00 Stage-1 228.00

Sodium Boro Hydride 19.50 Methanol Recovery 475.00



Hydrochloric Acid 18.80 Methanol loss 15.00

Methanol 500.00 Effluent water 834.03

Water 800.00 (Water-772.16 Boric acid-31.89 sodium chloride-29.98)

0


(Hydrogen-1.90) 0


Process Residue-12.37 Distillation Residue-10 (Methanol -10)

Total 1576.30 Total 1576.30

Material Balance RitonavirStage-2 Batch Size:250.0 Kg



Stage-1 228.00 Stage-2 262.00

Di –tert-Butyl oxydiformate 107.00 Methanol Recovery 475.00

Potassium carbonate 67.72 Methanol loss 15.00

MTBE 400.00 MTBE recovery 380.00

Methanol 500.00 MTBE loss 8.00

Hydrochloric acid 17.78 Effluent water 921.74

Water 800.00 (Water-800, Generated water-8.66 dipotassium tert-butyl carbonate-76.60 , Potassium chloride-36.48)

0




Process Residue-15.33 Distillation Residue-22 (Methanol -10,MTBE-12)

Total 2120.50 Total 2120.50


Batch Size:250.0 Kg



Stage-2 262.00 Stage-3 169.00

Ammonium Formate 29.00 Methanol Recovery + Toluene Recovery 85.40

560.40

Hydrogen gas 0.78 Methanol loss 15.00

Methanol 500.00 Effluent water 800.00

Water 800.00 (Water-800) 0


(Carbon dioxide-20.17 0



Ammonia-7.86)


Process Residue-9.35 Distillation Residue-10 (Methanol -10)

Total 1591.78 Total 1591.78


Batch Size:250.0 Kg



Stage-3 169.00 Stage-4 184.00

Succinic acid 25.85 IPA Recovery 475.00

Acetic acid 26.35 IPA loss 15.00

Sodium hydroxide 17.58 DMA Recovery 475.00

IPA 500.00 DMA loss 15.00

DMA 500.00 Effluent water 643.77

Water 600.00 (Water-600, Generated water-7.78, Sodium Acetate-35.99)

0


Process Residue-11.01 Distillation Residue-20 (IPA -10,DMA-10)

Total 1838.78 Total 1838.78


Batch Size:250.0 Kg



Thiourea 40.00 Stage-5 50.00

2-chloro-3-oxo-propionicacid ethyl ester

79.00 Methanol Recovery + Ethanol-22.42

497.42

Sodium boro hydride 18.40 Methanol loss 15.00

Hydrochloric acid 17.72 Iso amyl ntrite Recovery 285.00

Hydrogen 0.90 Iso amyl nitrite loss 6.00

Iso amyl nitrite 300.00 Spent palladium on carbon 10.00

Methanol 500.00 Effluent Water 691.78

Palladium on Carbon 10.00 (Water-633.15 Generated water-9.44 Sodium chloride-28.48, Boric acid-30.15)

0

Water 650.00 Process emission 28.86

(Ammonia-7.80 Hydrogen-1.94 Hydrogen chloride-19.12)

0


(Process Residue-12.96



Distillation Residue-19 (Methanol -10,Iso amyl Nitrite -9)

Total 1616.02 Total 1616.02


Batch Size:100.0 Kg



Stage-5 50.00 Stage-6 116.00

4-nitro phenyl chloro formate 87.50 Toluene Recovery 475.00

Sodium bi carbonate 36.45 Toluene loss 10.00

Pyridine 10.00 Ethyl acetate Recovery 475.00

Ethyl acetate 500.00 Ethyl acetate loss 10.00


Water 500.00 (Water-500, Generated water-7.80, Sodium chloride-25.35 Pyridine-10 Toluene-5, Ethyl acetate -5)

0




Process Residue-5.70 Distillation Residue-20 (Toluene -10,Ethylacetate-10)

Total 1683.95 Total 1683.95


Batch Size:250.0 Kg



Stage-6 116.00 Stage-7 205.00

Stage-4 184.00 Toluene Recovery 475.00

Methanol 500.00 Toluene loss 10.00

Toluene 500.00 Methanol Recovery 475.00

Water 1000.00 Methanol loss 15.00


(Water-1000, Hemi succnic acid-24.36, Toluene-5)

0


(Process Residue-70.64 Organic impurities -13.11 (4-nitrophenol-57.53) Distillation Residue-20 (Toluene -10,Methanol-10)



Total 2300.00 Total 2300.00


Batch Size:250.0 Kg



Iso butyramide 40.00 Stage-8 45.00

Phosphorus pentasulfide 20.40 Toluene Recovery 475.00

Sodium hydroxide 22.00 Toluene loss 10.00


Water 500.00 (Water-500, Generated water-4.92, Sodium phosphate-30.08, Toluene-5)

0


Process Residue-2.40 Distillation Residue-10 (Toluene -10)

Total 1082.40 Total 1082.40


Batch Size:250.0 Kg



Stage-8 45.00 Stage-9 70.00

1,3-Dichloro acetone 55.35 Toluene Recovery 475.00

Mono methyl amine 13.50 Toluene loss 10.00

Sodium hydroxide 52.30 Effluent water 912.87

Ammonium chloride 23.30 (Water-800, Generated water-31.42 Sodium chloride-76.45, Toluene-5)

0

Toluene 500.00 Process emission 7.42

Water 800.00 (Ammonia -7.42) 0


Process Residue-4.16 Distillation Residue-10 (Toluene -10)

Total 1489.45 Total 1489.45


Batch Size:250.0 Kg



Stage-9 70.00 Stage-10 122.00

(S)- methyl-3-methyl-2- ((4- 122.00 Methanol Recovery 475.00



Nitrophenoxy) carbonyl amino) butanoate

Lithium hydroxide 9.80 Methanol loss 10.00

Hydrochloric acid 14.98 Toluene Recovery 285.00

Methanol 500.00 Toluene Loss 10.00


Water 500.00 (Water-500, Lithium chloride-17.36,Toluene-3)

0


(Process Residue-77.42 Organic impurities-20.3 (4-Nitro phenol-57.12) Distillation Residue-17 (Methanol-15,Toluene-2)

Total 1516.78 Total 1516.78


Batch Size:250.0 Kg



Stage-10 122.00 Stage-11 265.00

Stage-7 205.00 THF Recovery 475.00

THF 500.00 THF loss 15.00


Water 500.00 Methanol loss 10.00


(Water-500, tert Butanol-28.80)

0


(carbon dioxide-17.08) 0


Process Residue-16.12 Distillation Residue-20 (THF-10,Methanol-10)

Total 1727.00 Total 1727.00


Batch Size:250.0 Kg



Stage-11 265.00 Ritonavir 250.00

n-Heptane 500.00 n-Heptane Recovery 475.00

Activated carbon 10.00 n-Heptane loss 10.00

hyflow 5.00 Effluent water 500.00

Water 500.00 (Water-500) 0

Spent carbon & hyflow 15.00




Process Residue-15 Distillation Residue-15 (n-Heptane -15)

Total 1280.00 Total 1280.00

SILDENAFIL CITRATE


Stage-1

Step-A

5-Propyl-2H pyrazole-3- carboxylic acid ethyl ester reacts with Dimethyl sulphate in

presence of MDC and Methanol to give Step-A Product.

Step-B

Step-A Product reacts with Sodium hydroxide in presence of Methanol to give Stage-

2 Product.

Stage-2

Stage-1 Product reacts with Nitric acid in presence of Sulfuric acid and water to give

stage-2 Product.

Stage-3

Stage-2 Product reacts with Thionyl chloride and Ammonium Hydroxide to give

Stage-3 product.

Step-4

Stage-3 Product reacts with stannous chloride in presence of Ethanol and HCl to

give Stage-4 Product.

Stage-5

Stage-4 Product reacts with 2-Ethoxy benzoyl chloride in presence of MDC to give

Stage-5 Product.

Stage-6

Stage-5 Product reacts with 5-(2-Aminomethoxy-phenyl)1—methyl-3-propyl-1,6-

dihydro-pyrazol[4,3-d]pyrimidin-7-one in presence of Methanol to give stage-6

Product.

Stage-7

Stage-6 Product reacts with Chloro sulfonic acid in presence of Methanol to give

stage-7 Product.

Stage-8

Stage-7 product condensed with 1-Methyl piperazine in presence of Toluene to give

stage-8 Product.

Stage-9

Stage-8 product undergoes salt formation with citric acid in presence of Methanol to

give Sildenafil Citrate.



Route of Synthesis:

Stage-1

Step-A

N

HN

CH3

O

OH3C

C9H14N2O2

182.22

+

Dimethyl sulphate

S

O

O

OCH3H3CO

126.13

N

CH3N

CH3

O

OH3C

S

O

O

OHH3CO

Methyl bisulfate

112.11

+

2-Methyl-5-propyl-2H-pyrazole-3-carboxylic acid ethyl ester

C10H16N2O2

196.25

5-Propyl-2H-pyrazole-3-carboxylic acid ethyl ester C2H6O4S

CH4O4S

Methanol, MDC

Step-B

N

CH3N

CH3

O

OH3C

C10H16N2O2

196.25

+ NaOH

40.0

N

CH3N

CH3

O

HO

CH3CH2ONa+

Sodium ethoxide

68.05

C8H12N2O2

168.19

2-Methyl-5-propyl-2H-pyrazole-3-carboxylic acid

ethyl ester

2-Methyl-5-propyl-2H-pyrazole-3-carboxylic acid



Stage-2

N

CH3N

CH3

O

HO

C8H12N2O2

168.19

+ HNO3

Nitric acid

63.01

N

CH3N

CH3

O

HO

O2N

C8H11N3O4

213.19

+ H2O

18.02

2-Methyl-5-propyl-2H-pyrazole-3-

carboxylic acid

2-Methyl-4-nitro-5-propyl-2H-pyrazole-3-carboxylic acid

Stage-3

N

CH3N

CH3

O

HO

O2N

C8H11N3O4

213.19

+ NH4OH

35.05

Ammonium hydroxide

+ SOCl2

Thionyl chloride

118.97

N

CH3N

CH3

O

H2N

O2N

C8H12N4O3

212.21

+ SO2

64.06

+ 2 HCl

2X36.5=73.0

+ H2O

18.02

2-Methyl-4-nitro-5-propyl-2H-pyrazole-3-carboxylic acid

2-Methyl-4-nitro-5-propyl-2H-pyrazole-3-

carboxylic acid amide



Stage-4

N

CH3N

CH3

O

H2N

O2N

C8H12N4O3

212.22

+ SnCl2

Stannous chloride

189.62

+ 2 HCl

2X36.5=73.0

N

CH3N

CH3

O

H2N

H2N

C8H14N4O

182.22

+ SnCl4

260.52

Stannic chloride

Ethanol

+ O2

32.0

2-Methyl-4-nitro-5-propyl-2H-pyrazole-3-

carboxylic acid amide

4-Amino-2-methyl-5-propyl-2H-pyrazole-

3-carboxylic acid amide

Stage-5

N

CH3N

CH3

O

H2N

H2N

C8H14N4O

182.22

+O

CH3

Cl

O

2-Ethoxy-benzoyl chloride

C9H9ClO2

184.62

NN

H2N O

CH3NH

O

O

CH3

CH3

4-(2-Ethoxy-benzoylamino)-2-methyl-5-propyl-2H-pyrazole-


C17H22N4O3

330.38

+ HCl

36.5

4-Amino-2-methyl-5-propyl-2H-pyrazole-3-carboxylic acid amide

Hydrogenchloride



Stage-6

NN

H2NO

CH3

NH

O

O

CH3

CH3

4-(2-Ethoxy-benzoylamino)-2-methyl-5-propyl-2H-pyrazole-


C17H22N4O3

330.38

O

CH3

N

HN

O

N

N

CH3

CH3

5-(2-Aminomethoxy-phenyl)-1-methyl-3-propyl-1,6-dihydro-pyrazolo[4,3-d]

pyrimidin-7-oneC17H20N4O2

312.37

Methanol+ H2O

18.02

Stage-7

O

CH3

N

HN

O

N

N

CH3

CH3

5-(2-Aminomethoxy-phenyl)-1-methyl-3-propyl-1,6-dihydro-pyrazolo[4,3-d]

pyrimidin-7-one

C17H20N4O2

312.37

Chloro Sulfonic acid

Cl

SO O

OH

+

ClHO3S

116.52

O

CH3

N

HN

O

N

N

CH3

CH3

SOO

Cl

4-Ethoxy-3-(1-methyl-7-oxo-3-propyl-6,7-dihydro-1H-pyrazolo[4,3-d]pyrimidin-5-yl)-

benzenesulfonyl chloride

C17H19ClN4O4S

410.88

+ H2O

18.02



Stage-8

O

CH3

N

HN

O

N

N

CH3

CH3

SOO

Cl

4-Ethoxy-3-(1-methyl-7-oxo-3-propyl-6,7-dihydro-1H-pyrazolo[4,3-d]pyrimidin-5-yl)-

benzenesulfonyl chloride

C17H19ClN4O4S

410.88

+

N

NH

H3C

1-Methyl-piperazine

C5H12N2

100.16

O

CH3

N

HN

O

N

N

CH3

CH3

SOO

N

N

H3C

Sildenafil

C22H30N6O4S

474.58

+ HCl

36.46



Stage-9

O

CH3

N

HN

O

N

N

CH3

CH3

SOO

N

N

H3C

Sildenafil

C22H30N6O4S

474.58

+

Citric acid

HO

OOH

O OH

O

HO

C6H8O7

192.12

Methanol

O

CH3

N

HN

O

N

N

CH3

CH3

SOO

N

N

H3C . HO

OOH

O OH

O

HO

C28H38N6O11S

666.70

Sildenafil Citrate



Flow chart:

4-Propyl -1h-pyrrole-2-carboxylic acid ethyl esterDi methylsulphateMethylene di chloride Methanol Sodium hydroxide

Stage-1Nitric acidSulfuric acid

Effluent Water

Stage-3Stannous ChlorideHydrochloric acidEthanolToluene

Effluent water

Stage-1

Stage-2

Stage-3

Methanol RecoveryMethylene di chloride Recovery

Ethanol RecoveryToluene Recovery

Stage-4

Stage-2Thionyl chloride Ammonium Hydroxide



Stage-42-Ethoxy-benzoyl chlorideMDC

MDC RecoveryStage-5

Methanol RecoveryToluene Recovery

Stage-6

Toluene RecoveryEffluent Water

Stage-7

Toluene RecoveryEffluent Water

Stage-8

Methanol RecoveryEffluent WaterStage-9

Stage-5MethanolToluene

Stage-6Chloro sulfonic acidToluene

Stage-71-methyl-piperazineToluene

Stage-8Citric acidMethanolActivated CarbonHyflow

Sildenafil Citrate



Material Balance:

Material balance of Sildenafil Citrate Stage-1

Batch size : 500kg

Name of the input Quantity in kg

Name of the out put Quantity in kg

4-Propyl -1h-pyrrole-2-carboxylic acid ethyl ester

375.00 Stage-1 297.00

Di methylsulphate 259.50 Methanol Recovery 475.00

Methylene di chloride 800.00 Methanol Loss 15.00

Methanol 500.00 Methylene di chloride Recovery 760.00

Sodium hydroxide 78.35 Methylene di chloride Loss 24.00


(Water-425, Sodium methoxide-

133.55 Methyl bi sulfate-230.62) 0


Process residue-51.68 Organic impurities-51.68 Distillation residue- 26 (MDC-16, Methanol-10)

Total 2437.85 Total 2437.85


Batch size : 500kg



Stage-1 297.00 Stage-2 338.00

Nitric acid 112.00 Effluent Water 431.78

Sulfuric acid 300.00 (Water-400,Generatedwater-

31.78) 0

Water + Ice 400.00 Spent Sulfuric acid 300.00



Total 1109.00 Total 1109.00


Batch size : 500.00kg



Stage-2 338.00 Stage-3 302.00

Thionyl chloride 188.60 Effluent water 328.39

Ammonium Hydroxide 55.45 (Water-300,

Generatedwater-28.39)

Ice + Water 300.00 Process emission 217.00



(Sulfur dioxide-101.40,

Hydrogen chloride-115.6)





Batch size:500.00kg



Stage-3 302.00 Stage-4 233.00

Stannous Chloride 269.65 Ethanol Recovery 475.00

Hydrochloric acid 103.58 Ethanol Loss 15.00

Ethanol 500.00 Toluene Recovery 570.00

Toluene 600.00 Toluene Loss 12.00


(Water-300,Stannicchloride-

370.55, Toluene-5) 0

Process Emission 45.30

(Oxygen-45.30) 0



Distillation Residue-23 (Ethanol-10, Toluene-13)

Total 2075.23 Total 2075.23


Batch size:500.00kg



Stage-4 233.00 Stage-5 380.00

2-Ethoxy-benzoyl chloride 236.00 MDC Recovery 570.00

MDC 600.00 MDC Loss 12.00


(Water-500) 0


(Hydrogen Chloride-46.60) 0



Distillation residue-18 (MDC-18)

Total 1569.00 Total 1569.00




Batch size:500.00kg



Stage-5 380.00 Stage-6 323.00


Toluene 600.00 Methanol Loss 10.00

Water 300.00 Toluene Recovery 570.00

Toluene Loss 12.00

Effluent Water 325.52

(Water-300,Generatedwater-

20.52, Toluene-5) 0



Distillation residue- 28 (Methanol-15, Toluene-13)

Total 1780.00 Total 1780.00


Batch size:500.00kg



Stage-6 323.00 Stage-7 382.00

Chloro sulfonic acid 120.45 Toluene Recovery 570.00



(Water-300,Generated water-

18.42, Toluene-5) 0



Distillation residue-13 (Toluene-13)

Total 1343.45 Total 1343.45


Batch size:500.00kg



Stage-7 382.00 Stage-8 396.00

1-methyl-piperazine 92.82 Toluene Recovery 570.00



(Water-300, Toluene-5) 0




(Hydrogen Chloride-33.62) 0



Distillation residue- 13 (Toluene-13)

Total 1374.82 Total 1374.82


Batch size:500.00kg



Stage-8 396.00 Sildenafil Citrate 500.00

Citric acid 160.00 Methanol Recovery 475.00


Activated Carbon 10.00 Effluent Water 300.00

Hyflow 5.00 (Water-300) 0

Water 300.00 Spent Carbon & Hyflow 15.00


Process residue-56,

Distillation residue- 15 (Methanol-15)

Total 1371.00 Total 1371.00

VALSARTAN

Process Description: Stage-1 Step-A:

L-Valine reacts with Thionyl chloride in presence of Toluene to give Step-A product.

Step-B:

Step-A Product reacts with Methanol in presence of water to give Stage-1 Product.

Stage-2:

Stage-1 product reacts with 4-Bromomethyl-biphenyl-2-carbonitrile in presence of

Toluene to give Stage-2 product.

Stage-3

Stage-2 product reacts with Valeryl chloride in presence of Toluene to give Stage-3

product.

Stage-4

Stage-3 product reacts with Sodium azide, Tri butyl tin chloride undergoes

Hydrogenation in presence of Toluene, MDC and n-Hexane t give Valsartan.

Route of Synthesis:



Stage-1

Step-A

L-Valine

C5H11NO2

117.15

NH2

CH3

H3C OH

O

+ SOCl2

NH2

CH3

H3C Cl

O

+ SO2

HCl

Thionyl Chloride

118.97

2-Amino-3-methyl-butyryl chloride hydrochloride

C5H11Cl2NO

172.05

64.06

Toluene

Step-B

NH2

CH3

H3C Cl

O

+

HCl

2-Amino-3-methyl-butyryl chloride

hydrochloride

C5H11Cl2NO

172.05

CH3OH

NH2

CH3

H3C OCH3

O HCl + HCl

32.04 2-Amino-3-methyl-butyric Acid methyl ester hydrochloride

36.46

C6H14NO2Cl

167.63

Methanol



Stage-2

NH2

CH3

H3C OCH3

O H

Cl

2-Amino-3-methyl-butyric Acid methyl ester hydrochloride

C6H14NO2Cl

167.63

4-Bromomethyl-biphenyl-2-carbonitrile

N

Br

+

N

O

O

NH

2-[(2-Cyano-biphenyl-4-ylmethyl)-amino]-3-methyl-butyric acid methyl ester

C14H10BrN

272.14

+

Potassium Carbonate

138.21

Toluene

C20H22N2O2

322.40

+ KBr +

K2CO3

KCl + CO2+ H2O

119.0 74.55 44.0 18.0



Stage-3

N

O

O

NH

2-[(2-Cyano-biphenyl-4-ylmethyl)-amino]-3-methyl-butyric acid methyl ester

C20H22N2O2

322.40

Valeryl Chloride

O

Cl+ + NaHCO3

Sodium bicarbonate

Toluene

C5H9ClO

120.58

84.0

O

O

N

N

O

2-[(2-Cyano-biphenyl-4-ylmethyl)-pentanoyl-amino]-3-methyl-butyric acid methyl ester

C25H30N2O3

406.52

+ NaCl + CO2+ H2O

58.44 44.0 18.0



Stage-4

O

O

N

N

O

2-[(2-Cyano-biphenyl-4-ylmethyl)-pentanoyl-amino]-3-methyl-butyric acid methyl ester

C25H30N2O3

406.52

O

OH

N

O

NN

HN

N

+ NaN3 +

Tributyl tin chloride

Sn

Cl

+ H2

Hydrogen Sodium Azide

2.0 65.0 C12H27ClSn

325.5

Valsartan

C24H29N5O3

435.5

+ Sn

H3C+ NaCl

Tributyl methyl stannane

C13H30Sn

305.0

58.46

TolueneMDC



Flow-Chart

Stage-1

Stage-2

L-ValineThionyl ChlorideMethanolToluene

Methanol RecoveryToluene Recovery

Stage-14-Bromomethyl-biphenyl-2-carbonitrilePotassium carbonateToluene

Toluene RecoveryEffluent water

Stage-2Valeryl ChlorideTolueneTEASodium bicarbonateSodium Sulphate

Stage-3Toluene RecoveryEffluent water

Stage-3Sodium AzideTri butyl tin chlorideHydrogen Sodium hydroxideXyleneTolueneMDCN-HexaneActivated Carbon

Stage-4

Xylene RecoveryMDC RecoveryToluene RecoveryEffluent watetr

VALSARTAN

Material Balance:

Material Balance of Valsartan Stage-1

Batch Size: 500Kg



L-Valine 154.00 Stgae-1 208.00

Thionyl Chloride 157.00 Methanol Recovery 475.00


Toluene 400.00 Toluene Recovery 380.00

Toluene Loss 10.00


(Sulfur dioxide-84.21, Hydrogen Chloride-46.62)

0




Process residue -13.17, Distillation residue -25 (Methanol-15, Toluene-10)

Total 1252.00 Total 1252.00


Batch Size: 500Kg



Stage-1 208.00 Stage-2 390.00

4-Bromomethyl-biphenyl-2-carbonitrile

338.00 Toluene Recovery 570.0

Potassium carbonate 172.00 Toluene Loss 20.00

Toluene 600.00 Effluent Water 1067.48

Water 800.00 (Water-800,Generated water-22.33, Potassium chloride-92.50, Potassium Bromide-147.65, Toluene-5)

0




Process residue -10.92 Distillation residue -5 (Toluene-5)

Total 2118.00 Total 2118.00


Batch Size: 500Kg



Stage-2 390.00 Stage-3 480.00

Valeryl Chloride 146.00 Toluene Recovery 665.00


TEA 20.00 Effluent Water 820.77

Sodium bicarbonate 102.00 (Water-700,Generated water-21.77, Sodium chloride-71, TEA-20,Toluene-8)

0

Sodium Sulphate 10.00 Inorganic Solid Waste 10.00

Water 700.00 (Sodium Sulphate) 0




Process residue -12.01 Distillation residue -7 (Toluene-7)

Total 2068.00 Total 2068.00




Batch Size: 500Kg



Stage-3 480.00 Valsartan Pharma 500.00

Sodium Azide 77.00 Toluene Recovery 665.00

Tri butyl tin chloride 385.00 Toluene Loss 20.00

Hydrogen 2.50 MDC Recovery 475.00

Sodium hydroxide 20.00 MDC Loss 15.00

Xylene 240.00 Xylene Recovery 228.00

Toluene 700.00 Xylene Loss 12.00

MDC 500.00 N-Hexane Recovery 190.00

N-Hexane 200.00 N-Hexane Loss 10.00

Activated Carbon 10.00 Effluent Water 1087.00

Water 1000.00 (Water-1000, Sodium Chloride-69,Toluene-8, Acetic Acid-10)

0

Spent Carbon 10.00


Process residue –385.50 Organic Impurities-25.50 (Tri butyl-methyl –stannane-360) Distillation residue- 17 (Toluene-7, MDC-10)

Total 3614.50 Total 3614.50

2.7 POLLUTION LOAD

Pollution load and generation of waste per day from all the proposed products is

given in below Table 2.4



Table 2.4: CONSOLIDATED POLLUTION LOAD OF ALL PRODUCTS IN KG PER DAY

SNo

Product Name

Production

capacity kg/

Month

Effluent in kg/day Solid waste Details in

Kg/day Distillat

ion Residue in Kg

/Day

Emissions in Kg/day

Water Input

Water In Effluent

Inorganics in

water

Organics in

water

TDS COD HTDS LTDS Total

Effluent Organic

Inorganic

Spent carbo

n

Process

Fugitive

1 Atorvastatin Calcium

10000 2333.33 2329.76 4.67 48.28 4.67 42.35 0.00 2382.71 2382.71 82.06 0.00 6.00 4.67 0.00 48.00

2 Dapoxetine Hydrochloride

4000 2800.00 2817.64 185.19 0.00 185.19 0.00 1936.16 1066.67 3002.83 33.41 53.33 0.00 1.33 74.92 169.33

3 D-penicillamine

5000 2083.33 2083.33 0.00 2.50 0.00 2.61 0.00 2085.83 2085.83 18.93 0.83 12.50 5.83 0.00 22.50


5000 2750.00 2740.00 26.92 71.48 26.92 151.92 2838.39 0.00 2838.39 14.28 8.33 0.00 15.00 60.53 185.00

5 Lansoprazole 10000 1866.67 2034.77 123.80 191.73 123.80 121.41 1206.07 1144.23 2350.30 76.11 205.80 3.33 28.67 101.79 41.33

6 Lopinavir 5000 1366.67 1650.40 370.63 69.33 370.63 195.20 1757.03 333.33 2090.36 73.26 208.60 4.00 62.00 100.60 218.67

7 Moxifloxacin hydrochloride

2000 1000.00 1000.00 0.67 2.00 0.67 3.00 0.00 1002.67 1002.67 32.57 0.00 3.33 0.00 0.00 26.67

8 Nebivolol 5000 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 103.80 16.67 0.00 5.00 0.00 85.42

9 Ritonavir 5000 5300.00 5310.59 278.12 61.86 278.12 128.61 4002.19 1648.38 5650.57 174.97 0.00 16.67 128.67 82.55 149.33

10

Sildenafil citrate

15000 3125.00 3224.11 734.72 20.00 734.72 62.60 1464.72 2514.11 3978.83 375.05 0.00 15.00 136.00 342.52 134.00

11

Valsartan 15000 2500.00 2544.10 380.15 51.00 380.15 133.43 2975.25 0.00 2975.25 421.60 10.00 10.00 54.00 238.65 117.00

Total 81000 25125.00 25734.71 2104.85 518.18 2104.85 841.12 16179.82 12177.92 28357.74 1406.05 503.57 70.83 441.17

1001.56

1197.25



Pollution loads have been calculated for each product based on chemical reactions,

material balance and subsequent process operations to get the required quantity.

2.8 Description of Process Emissions and its mitigation measures

The Predicted Process emissions are SO2, CO2, CH3Cl, HCl, HF, HBr, H2, NH3 & O2

which will liberate from manufacturing process of proposed products. The process

emissions are based on reactants quantity and chemical reactions between them in

relation with desired product output.

To meet the environmental standards, double stage scrubbers as a single unit is

proposed. During plant operations samples will be collected to check whether

process emissions are within limits.

TABLE 2.5: Process Emission details and Treatment Method







5 Hydrogen 16 Diffused by using Nitrogen through Flame arrestor







TABLE-: 2.6 PROCESS EMISSION DETAILS - PRODUCT WISE

S.No. Product Name Production

Capacity Kg/ Month

Kg Per Day

CO2 SO2 H2 HCl O2 HF CH3Cl NH3 HBr

1 Atorvastatin Calcium 10000 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

2 Dapoxetine Hydrochloride 4000 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 74.92

3 D-penicillamine 5000 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

4 Duloxetine Hydrochloride 5000 23.28 0.00 0.00 0.00 0.00 10.52 26.72 0.00 0.00

5 Lansoprazole 10000 0.00 65.00 0.00 36.79 0.00 0.00 0.00 0.00 0.00

6 Lopinavir 5000 44.55 0.00 13.40 30.65 0.00 0.00 0.00 12.00 0.00

7 Moxifloxacin hydrochloride 2000 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

8 Nebivolol 5000 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

9 Ritonavir 5000 51.85 0.00 2.56 12.75 0.00 0.00 0.00 15.39 0.00

10 Sildenafil citrate 15000 0.00 101.40 0.00 195.82 45.30 0.00 0.00 0.00 0.00

11 Valsartan 15000 107.82 84.21 0.00 46.62 0.00 0.00 0.00 0.00 0.00

Total 81000 227.50 250.61 15.96 322.63 45.30 10.52 26.72 27.39 74.92



2.9 PROPOSED WATER CONSUMPTION DETAILS

Total water consumption for the proposed project is 134.13 KLD. Water consumption

details are given in below Table. No. 2.7

TABLE- 2.7: Proposed Water Consumption details


Total Fresh water reuirement = 134.13-43.50

= 90.63 KLD


TABLE- 2.8: PROPOSED WATER CONSUMPTION IN PROCESS

– PRODUCT WISE

S.No Product Name Productioncapacity kg/ Month

Water Input in kg/day

1 Atorvastatin Calcium 10000 2333.33

2 Dapoxetine Hydrochloride 4000 2800.00

3 D-penicillamine 5000 2083.33

4 Duloxetine Hydrochloride 5000 2750.00

5 Lansoprazole 10000 1866.67

6 Lopinavir 5000 1366.67

7 Moxifloxacin hydrochloride 2000 1000.00

8 Nebivolol 5000 0.00

9 Ritonavir 5000 5300.00

10 Sildenafil citrate 15000 3125.00

11 Valsartan 15000 2500.00

Total 81000 25125.00

S. No Purpose Water

Input in KLD

1 Process 25.13

2 Washings 5.00




6 Domestic 5.00

7 Gardening 3.00

Total 134.13



2.10 EXPECTED WASTE WATER GENERATION DETAILS

TABLE-2.9: Expected Effluent generation details

S. No Purpose Effluent in KLD

1 Process 28.36

2 Washings 5.00


4 Cooling towers blow down

7.00


6 Domestic 4.50

Total 52.86

TABLE-2.10: Expected HTDS & LTDS Effluent Generation Details

Unit HTDS KLD

LTDS KLD

Effluent Generation


Process 16.18 12.18 28.36 HTDS Effluent sent to stripper

followed by MEE system.

LTDS effluents treated in ETP along with MEE condensate. Treated effluent is sent to RO, RO permeate water is recycled and RO rejects taken for evaporation in MEE followed by ATFD to collect evaporation salts for disposal to TSDF.

Washings 0.00 5.00 5.00




Domestic 0.00 4.50 4.50

Total 19.18 33.68 52.86

The generations of process effluent water HTDS & LTDS and its characteristics are

based on reactants quantity and chemical reactions between them in relation with

desired product output.

The Boiler & Cooling towers blow down water will have TDS less than 5000 mg/l and

scrubbing solution will have TDS more than 5000 mg/l. Floor washings and

equipment washings will have TDS less than 5000 mg/l.



TABLE- 2.11 WASTEWATER GENERATIONS IN KGS PER DAY - PRODUCT WISE

S.No Product Name Production capacity kg/

Month

Effluent in kg/day

Water In Effluent

Inorganics in water

Organics in water

TDS COD HTDS LTDS Total

Effluent


10000 2329.76 4.67 48.28 4.67 42.35 0.00 2382.71 2382.71


4000 2817.64 185.19 0.00 185.19 0.00 1936.16 1066.67 3002.83

3 D-penicillamine 5000 2083.33 0.00 2.50 0.00 2.61 0.00 2085.83 2085.83


5000 2740.00 26.92 71.48 26.92 151.92 2838.39 0.00 2838.39

5 Lansoprazole 10000 2034.77 123.80 191.73 123.80 121.41 1206.07 1144.23 2350.30

6 Lopinavir 5000 1650.40 370.63 69.33 370.63 195.20 1757.03 333.33 2090.36


2000 1000.00 0.67 2.00 0.67 3.00 0.00 1002.67 1002.67

8 Nebivolol 5000 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

9 Ritonavir 5000 5310.59 278.12 61.86 278.12 128.61 4002.19 1648.38 5650.57

10 Sildenafil citrate 15000 3224.11 734.72 20.00 734.72 62.60 1464.72 2514.11 3978.83

11 Valsartan 15000 2544.10 380.15 51.00 380.15 133.43 2975.25 0.00 2975.25

Total 81000 25734.71 2104.85 518.18 2104.85 841.12 16179.82 12177.92 28357.74



2.11 Expected Effluent water charact eristics:

*We are going to achieve zero discharge system.

The effluent water characteristics before treatment are based on calculations. The

effluent water after passing through Stripper, MEE, Biological treatment plant & RO

plant the expected results after treatment are given in the above table.

2.12 HAZARDOUS & SOLID WASTE GENERATION DETAILS

The Hazardous & Solid waste generated and disposal methods from proposed


TABLE- 2.12: EXPECTED HAZARDOUS & SOLID WASTE GENERATION,

DISPOSAL DETAILS




1406


2 Spent Carbon 71



380



8 MEE Salts 2868




Solid Waste Details


S. No Parameters Unit Results

Before treatment

After treatment

1. pH - 8.5-9.0 6.5 – 8.5

2. HTDS mg/L 29973 700 - 900

3. LTDS mg/L 25103 <500

4. COD mg/L 2621 <250

5. Oil & Grease mg/L 20-25 <10



The expected quantities which are given in the above table based on calculations of

each product material balance. The ash from boiler is based on ash percentage in

the coal. The used oils and used lead acid batteries quantities are based on usage of

respective equipment. The container liners & containers are based on various

packing of raw materials.

TABLE- 2.13: SOLID WASTE GENERATION – PRODUCT WISE PER DAY

S.No Product Name Productioncapacity

kg/Month

Solid waste Details in Kg/day Distillation Residue in

Kg /Day Organic Inorganic

Spent carbon


10000 82.06 0.00 6.00 4.67


4000 33.41 53.33 0.00 1.33

3 D-penicillamine 5000 18.93 0.83 12.50 5.83


5000 14.28 8.33 0.00 15.00

5 Lansoprazole 10000 76.11 205.80 3.33 28.67

6 Lopinavir 5000 73.26 208.60 4.00 62.00


2000 32.57 0.00 3.33 0.00

8 Nebivolol 5000 103.80 16.67 0.00 5.00

9 Ritonavir 5000 174.97 0.00 16.67 128.67

10 Sildenafil citrate 15000 375.05 0.00 15.00 136.00

11 Valsartan 15000. 421.60 10.00 10.00 54.00

Total 81000 1406.05 503.57 70.83 441.17

2.13 POWER (ENERGY) REQUIREMENT

Power requirement of proposed project will be made available through Telangana

State Power Distribution Company Limited [TSPDCL]. The power requirement of

project will be 2000 KVA.

2.14 UTILITIES

TABLE - 2.14: Details of Utilities

S. No Description Capacity

1 Coal fired boiler 2 TPH & 3 TPH

3 D.G. Set 1 x 500 KVA

4 Cooling Towers 3 x 200 TR

& 1 x 300 TR

5 Electricity supply from TSPDCL

2000 KVA



2.15 PROPOSED BOILER & DG SET

For generation of Steam, the industry proposed to install 2 TPH & 3 TPH Coal fired


The unit is proposing a 500 KVA DG set, for usage during the power failures.

TABLE- 2.15: Emission Characteristic details of proposed Boilers



Boiler


5000 kcal/kg


5000 kcal/kg


Ash Content % 35 35










TABLE- 2.16: Stack Emission details of proposed DG Set

Capacity In KVA




Stack dia. In m

Flue Gas Temp. in

OC

Stack Height in (m)


500 KVA 60 85 110 0.2 300 10 14

Fuel

6 Coal 15.5 TPD

7 Diesel 80 Liters/Day



2.16 DETAILS OF PROPOSED SOLVENTS INPUT, RECOVERY & LOSS

A liquid substance capable of dissolving other substances; "the solvent does not change its state in forming a solution". Details of

solvents are given below in a table 2.17.

TABLE 2.17: DETAILS OF PROPOSED SOLVENT INPUT, RECOVERY & LOSS [PRODUCT WISE]

S.No Product Name Production

capacity Kg/Month

Quantity in Kgs/Day

Solvent Name Solvent

Input Solvent

Recovery Solvent

Loss

Solvent in

waste water

Solvent in

Residue

1 Atorvastatin Calcium 10000 Methanol 306.67 288.00 15.33 0.00 3.33

Cyclohexane 133.33 126.67 6.67 0.00 0.00

IPA 200.00 190.67 9.33 0.00 0.00

Acetonitrile 200.00 190.00 10.00 0.00 0.00

Toluene 133.33 123.33 6.67 2.00 1.33

Total 973.33 918.67 48.00 2.00 4.67

2 Dapoxetine Hydrochloride 4000 Methanol 353.33 334.67 17.33 0.00 1.33

Diethyl ether 1400.00 1330.67 69.33 0.00 0.00

carbon tetra hydrochloride

333.33 317.33 16.00 0.00 0.00

Ethanol 1066.67 1013.33 53.33 0.00 0.00

Ethyl acetate 133.33 120.00 13.33 0.00 0.00

Total 3286.67 3116.00 169.33 0.00 1.33

3 D-penicillamine 5000 Methanol 333.33 320.83 8.33 0.00 4.17

Toluene 291.67 277.50 10.00 2.50 1.67

EDC 250.00 245.83 4.17 0.00 0.00

Total 875.00 844.17 22.50 2.50 5.83

4 Duloxetine Hydrochloride 5000 Ethyl acetate 1300.00 1233.33 65.00 0.00 1.67

MDC 166.67 154.17 8.33 0.00 4.17

Cyclo hexane 316.67 300.83 15.83 0.00 0.00

Toluene 1666.67 1570.83 83.33 3.33 9.17



IPA 250.00 237.50 12.50 0.00 0.00

Total 3700.00 3496.67 185.00 3.33 15.00

5 Lansoprazole 10000 Toluene 600.00 570.00 16.67 3.33 10.00

MIBK 100.00 93.33 3.33 0.00 3.33

MDC 266.67 253.33 8.00 0.00 5.33

IPA 166.67 158.67 3.33 0.00 4.67

Chloroform 266.67 256.00 8.00 0.00 2.67

Acetone 100.00 95.33 2.00 0.00 2.67

Total 1500.00 1426.67 41.33 3.33 28.67

6 Lopinavir 5000 n-Heptane 166.67 158.67 8.00 0.00 0.00

MTBE 900.00 855.33 44.67 0.00 0.00

Methanol 600.00 570.00 16.67 0.00 13.33

Ethanol 933.33 886.67 30.00 0.00 16.67

THF 600.00 570.00 16.67 0.00 13.33

IPA 200.00 190.00 10.00 0.00 0.00

Ethyl acetate 1066.67 1013.33 42.67 5.33 5.33

MDC 400.00 380.00 8.00 0.00 12.00

Dimethyl acetamide 106.67 101.33 5.33 0.00 0.00

1,2-Dimethoxy ethane

200.00 190.00 10.00 0.00 0.00

DMF 200.00 190.00 10.00 0.00 0.00

Acetone 333.33 315.33 16.67 0.00 1.33

Total 5706.67 5420.67 218.67 5.33 62.00

7 Moxifloxacin hydrochloride 2000 Acetone 133.33 126.67 6.67 0.00 0.00

DMF 66.67 63.33 3.33 0.00 0.00

Methanol 333.33 316.67 16.67 0.00 0.00

Total 533.33 506.67 26.67 0.00 0.00

8 Nebivolol 5000 Hexane 250.00 237.50 12.50 0.00 0.00

Ethyl acetate 250.00 235.83 12.50 0.00 1.67

IPA 250.00 235.83 12.50 0.00 1.67

Methanol 500.00 473.33 25.00 0.00 1.67

DIPE 250.00 237.50 12.50 0.00 0.00

Acetonitrile 208.33 197.92 10.42 0.00 0.00

Total 1708.33 1617.92 85.42 0.00 5.00



9 Ritonavir 5000 Methanol 2266.67 2153.33 63.33 0.00 50.00

MTBE 266.67 253.33 5.33 0.00 8.00

IPA 333.33 316.67 10.00 0.00 6.67

DMA 333.33 316.67 10.00 0.00 6.67

Isoamyl nitrite 200.00 190.00 4.00 0.00 6.00

Toluene 1533.33 1456.67 33.33 15.33 28.00

Ethyl acetate 333.33 316.67 6.67 3.33 6.67

THF 333.33 316.67 10.00 0.00 6.67

n-Heptane 333.33 316.67 6.67 0.00 10.00

Total 5933.33 5636.67 149.33 18.67 128.67

10 Sildenafil citrate 15000 Methanol 1500.00 1425.00 35.00 0.00 40.00

MDC 1400.00 1330.00 36.00 0.00 34.00

Ethanol 500.00 475.00 15.00 0.00 10.00

Toluene 2400.00 2280.00 48.00 20.00 52.00

Total 5800.00 5510.00 134.00 20.00 136.00

11 Valsartan 15000 Methanol 500.00 475.00 10.00 0.00 15.00

Toluene 2400.00 2280.00 70.00 21.00 29.00

MDC 500.00 475.00 15.00 0.00 10.00

Xylene 240.00 228.00 12.00 0.00 0.00

n-Hexane 200.00 190.00 10.00 0.00 0.00

Total 3840.00 3648.00 117.00 21.00 54.00

Grand Total 33856.67 32142.08 1197.25 76.17 441.17



2.17 LIST OF THE RAW MATERIALS PRODUCT WISE

ATORVASTATIN CALCIUM

S .No. Raw Material Consumption/ Batch in Kgs

Consumption/ Day in Kgs

1

(6-Cyanomethyl-2,2-dimethyl- [1,3]dioxan-4-yl)-acetic acid tert-butyl ester

252.00 168.00

2

4-(4-fluorophenyl)-2-isobutyryl-3 phenyl -4-oxo-N-phenyl-butyramide

378.50 252.33

3 Acetonitrile 300.00 200.00

4 Activated carbon 5.00 3.33

5 Calcium acetate 66.82 44.55

6 cyclohexane 200.00 133.33

7 Hydrochloric acid 3.36 2.24

8 Hydrogen 0.68 0.45

9 Hyflow 3.00 2.00

10 IPA 150.00 100.00

11 Isopropylalcohol 150.00 100.00

12 Methanol 460.00 306.67

13 Pivalic acid 2.00 1.33

14 Raney Nickel 1.00 0.67

15 Sodium carbonate 7.00 4.67

16 Sodium hydroxide flakes

33.95 22.63

17 Toluene 200.00 133.33




1 1-Naphthol 106.00 141.33

2 3-Phenylpropyl bromide

147.00 196.00

3 Carbon tetra hydrochloride

250.00 333.33

4 Di methyl amine 32.00 42.67

5 Diethyl ether 1050.00 1400.00

6 Ethanol 800.00 1066.67

7 Ethyl acetate 100.00 133.33

8 IPA.HCl 2.00 2.67

9 Methanol 265.00 353.33

10 N-Bromo succinamide 127.00 169.33

11 Potassium hydroxide 42.00 56.00

12 Sodium hydroxide 1.00 1.33

13 Sodium sulphate 40.00 53.33

14 Tartaric acid 51.00 68.00



D-PENICILLAMINE



1 Peniloic acid 460.00 383.33

2 Acetic acid 89.55 74.63


4 Aniline 139.00 115.83

5 EDC 300.00 250.00

6 Hyflow 1.00 0.83

7 Methanol 400.00 333.33

8 Toluene 300.00 250.00




1 3-Dimethylamino-1-thiophen-2-yl-propan-1-ol

237.00 197.50

2 1-FluoroNapthalene 93.00 77.50

3 Cyclo hexane 380.00 316.67

4 Dichloromethane 200.00 166.67

5 DMSO 7.00 5.83

6 Ethyl acetate 1560.00 1300.00


8 Isopropyl alcohol 300.00 250.00

9 L(+) Mandelic acid 98.00 81.67

10 Methanol 4.00 3.33

11 Oxalic acid 68.00 56.67

12 Phenyl chloroformate 100.00 83.33

13 Sodium carbonate 5.60 4.67

14 Sodium chloride 10.00 8.33


16 Sodium sulfate 10.00 8.33

17 TBAB 3.00 2.50

18 TEA 5.00 4.17

19 Toluene 2000.00 1666.67

LANSOPRAZOLE



1 2,3-Lutidine 188.00 125.33

2 1,1,2-Tri Fluoro Ethanol

167.00 111.33

3 1H-Benzoimidazole-2thiol

226.00 150.67

4 Acetic Acid 46.00 30.67

5 Acetic Anhydride 170.00 113.33



6 Acetone 150.00 100.00

7 Activated Carbon 5.00 3.33

8 Catalyst 1.00 0.67

9 Chloroform 400.00 266.67

10 Hydrogen Chloride 61.00 40.67

11 Hydrogen Peroxide (50%)

178.00 118.67

12 Isopropyl Alcohol 250.00 166.67

13 Methylene Dichloride 400.00 266.67

14 MIBK 150.00 100.00

15 Nitric Acid 111.00 74.00

16 Potassium Carbonate 230.00 153.33

17 Sodium Hydroxide 188.00 125.33

18 Sulfuric Acid 50.00 33.33

19 TEBAC 1.00 0.67

20 Thionyl Chloride 180.00 120.00

21 Toluene 900.00 600.00

LOPINAVIR



1 (R)-2-amino-3-phenyl propanoic acid

103.00 85.83

2 1,2-Dimethoxy ethane 300.00 250.00

3 2,6-Dimethyl phenoxy acetyl chloride (DPC)

85.50 71.25

4 Acetone 500.00 416.67



7 Ammonium chloride 200.00 166.67

8 Ammonium formate 29.48 24.57

9 Benzyl chloride 237.00 197.50

10 Benzyl magnesium chloride

85.90 71.58

11 Citric acid monohydrate

124.85 104.04

12 Citric acid monohydrate

119.70 99.75

13 Dimethyl acetamide 160.00 133.33

14 DMF 300.00 250.00

15 Ethanol 1400.00 1166.67

16 Ethyl acetate 1600.00 1333.33


18 Hydrogen gas 3.29 2.74

19 Hyflow 5.00 4.17

20 Imidazole 39.65 33.04

21 IPA 300.00 250.00

22 L-Pyro glutamic acid 57.96 48.30



23 MDC 600.00 500.00

24 Methane sulphonic acid

7.00 5.83

25 Methanol 900.00 750.00

26 Methyl chloro formate 60.45 50.38

27 MTBE 1350.00 1125.00

28 n-Heptane 250.00 208.33

29 Palladium carbon 20.60 17.17

30 Potassium carbonate 86.00 71.67

31 Raney Nickel 5.00 4.17

32 Sodamide 23.00 19.17

33 Sodium bicarbonate (10%)

362.50 302.08

34 Sodium Boro hydride 20.65 17.21

35 Sodium chloride 133.20 111.00

36 Sodium sulphate 20.00 16.67

37 THF 900.00 750.00

38 TPA 55.00 45.83

39 Triethyl amine 96.00 80.00

40 Valina 75.00 62.50

MOXIFLOXACIN HYDROCHLORIDE



1 Moxifloxacin Q-Acid 80.00 53.33

2 2,8-Diazobicyclo(4.3.0) nonane

34.50 23.00

3 Acetone 200.00 133.33


5 Dimethylformamide 100.00 66.67

6 EDTA 1.00 0.67


8 Methanol 500.00 333.33

9 Triethylamine 27.35 18.23




1 6-Fluoro-2-oxiranyl-chroman

198.00 165.00


3 Benzylamine 52.90 44.08

4 DIPE 300.00 250.00


6 Hexane 300.00 250.00


9 Hyflow 0.50 0.42



10 IPA 300.00 250.00

11 IPA.HCl 44.62 37.18

12 Methanol 600.00 500.00

13 Palladium Catalyst 2.00 1.67

14 Silicagel 20.00 16.67

RITONAVIR



1 (R,Z)-5-amino-2-(dibenzyl amino) -1,6-diphenyl hex-4-en-3-one

238.00 198.33

2

(S)- methyl-3-methyl-2- ((4-Nitrophenoxy) carbonyl amino) butanoate

122.00 101.67

3 1,3-Dichloro acetone 55.35 46.13

4 2-chloro-3-oxo-propionicacid ethyl ester

79.00 65.83

5 4-nitro phenyl chloro formate

87.50 72.92

6 Acetic acid 26.35 21.96


8 Ammonium chloride 23.30 19.42

9 Ammonium Formate 29.00 24.17

10 Di –tert-Butyl oxydiformate

107.00 89.17

11 DMA 500.00 416.67


13 Hydrochloric Acid 69.28 57.73

14 Hydrogen 1.68 1.40

15 hyflow 5.00 4.17

16 IPA 500.00 416.67

17 Iso amyl nitrite 300.00 250.00

18 Iso butyramide 40.00 33.33

19 Lithium hydroxide 9.80 8.17

20 Methanol 3400.00 2833.33

21 Mono methyl amine 13.50 11.25

22 MTBE 400.00 333.33

23 n-Heptane 500.00 416.67

24 Palladium on Carbon 10.00 8.33

25 Phosphorus pentasulfide 20.40 17.00


27 Pyridine 10.00 8.33

28 Sodium bi carbonate 36.45 30.38

29 Sodium Boro Hydride 37.90 31.58


31 Succinic acid 25.85 21.54



32 THF 500.00 416.67

33 Thiourea 40.00 33.33

34 Toluene 2300.00 1916.67

SILDENAFIL CITRATE



1 4-Propyl -1h-pyrrole-2-carboxylic acid ethyl ester

375.00 375.00

2 1-methyl-piperazine 92.82 92.82

3 2-Ethoxy-benzoyl chloride 236.00 236.00


5 Ammonium Hydroxide 55.45 55.45

6 Chloro sulfonic acid 120.45 120.45

7 Citric acid 160.00 160.00

8 Di methylsulphate 259.50 259.50

9 Ethanol 500.00 500.00


11 Hyflow 5.00 5.00

12 MDC 600.00 600.00

13 Methanol 1500.00 1500.00

14 Methylene di chloride 800.00 800.00

15 Nitric acid 112.00 112.00


17 Stannous Chloride 269.65 269.65

18 Sulfuric acid 300.00 300.00

19 Thionyl chloride 188.60 188.60

20 Toluene 2400.00 2400.00

VALSARTAN



1 L-Valine 154.00 154.00

2 4-Bromomethyl-biphenyl-2-carbonitrile

338.00 338.00



5 MDC 500.00 500.00

6 Methanol 541.00 541.00

7 N-Hexane 200.00 200.00


9 Sodium Azide 77.00 77.00

10 Sodium bicarbonate 102.00 102.00


12 Sodium Sulphate 10.00 10.00

13 TEA 20.00 20.00

14 Thionyl Chloride 157.00 157.00



15 Toluene 6.00 2400.00

16 Tri butyl tin chloride 385.00 385.00

17 Valeryl Chloride 146.00 146.00

18 Xylene 240.00 240.00

2.18 ENVIRONMENTAL ASPECTS, IMPACTS AND MITIGATION MEASURES OF

PROPOSED INDUSTRY

1. Aspect: Process gases such as SO2, HCl, HBr, NH3, HF & CH3Cl Emissions, DG

Set emissions & Boiler emissions into atmosphere.

Impact: Air pollution & Acid precipitation.

Mitigation measures: During production process the released gases will be

passed through double stage scrubber to scrub the gases with miscible liquid.

The scrubber will have polypropylene rings as packing media to increase the

contact surface area between gas and scrubbing solution to increase the

absorption. Gas and scrubbing solution will pass through the scrubber counter

currently.

SO2 gas will be scrubbed with caustic lye solution to convert into sodium

sulphate. In this process the entire SO2 will get scrubbed.

HBr, HF & CH3Cl are scrubbed by using C. S. Lye solution.

HCl gas will be scrubbed with chilled water to convert into HCl solution.

NH3 will be scrubbed with chilled water to convert into ammonium solution.

DG set emissions will be monitored regularly to maintain the emission limits

within the CPCB limits. As per norms the stack height will be provided around 10

mts to have proper dispersion. In case the limits are crossing the combustion

engine will be taken for service.

Boiler flue gases emissions will be monitored regularly to maintain the flue gases

emission limit as per CPCB Standard. The stacks of height 30 m each will be

provided to have proper dispersion of flue gases.

2. Aspect: Organic & inorganic impurities from process & inorganic impurities High

TDS water & High COD water from utilities, floor washings entering into water

stream.

Impact: water pollution (contamination of natural resources)

Mitigation measures: The generated High & Low TDS water, floor washings will

be collected in separate streams at generation point and collected in to



respective dedicated tanks. The high TDS water sent through the MEE System to

remove COD and TDS and later passed with Low TDS water through the

Biological treatment plant to remove BOD and finally through the RO plant to get

reusable water quality. This water will be used for Cooling towers and floor

washings etc. This will minimize the fresh water requirement to 90.63 KLD.

3. Aspect: Noise from DG Set, Boiler & Electric motors more than 75 dB.

Impact: Noise pollution.

Mitigation measure: DG set will have acoustic enclosure and drives will have

proper maintenance to minimize vibrations and internal parts servicing to

minimize the sound pollution.

4. Aspect: Spillages of chemicals during loading /unloading, Effluent water at ETP

Plant, Solvents spillages at storage tanks, spillage of Oils from DG Set & Air

compressor/Refrigeration compressor on to the ground.

Impact: Soil pollution.

Mitigation measure: To avoid any spillage of chemicals the working area of

loading & unloading area is barricaded and the floor will be made with acid proof

tiling with a slope towards a small pit so as to collect the spilled chemicals in the

dedicated pit. This results in avoiding the spillage of chemicals on to the ground.

Effluent water will be transferred through the dedicated pipe lines from plant to

ETP plant. This will eliminate soil contamination with effluent water.

Each solvent storage tank area will have dyke wall and the floor will have cement

concrete with slope towards a pit. Hence spillage of solvent will be avoided on to

ground.

The DG set /Air compressor/refrigeration compressor area will be placed in

Utilities building with cement concrete floor. The filling and draining of Oils from

respective equipment will be done by trained technical person to avoid any

spillage of oil on to the floor/ground.

5. Aspect: Improper Storage of hazardous waste (organic waste, inorganic waste,

spent carbon) results in leakage/Spillage on to the ground

Impact: Soil pollution

Mitigation measure: The hazardous waste in containers will be stored in

dedicated area as per its category with proper flooring having slope towards a pit



to collect any spilled material. The entire area will be barricaded with a dyke wall

and only authorized personnel will be allowed to do operations in storage area.

This avoids soil pollution.

6. Aspect: Establishment of industry may release gases emissions, effluent water

leakage to surrounding areas.

Impact: 1. Flora & Fauna, Water Bodies, Agriculture & Human habitation.

2. The positive impact is generation of employment to skilled & unskilled

people of nearby villages and economic development.

Mitigation measure: The industry will have dedicated effluent treatment (MEE,

Biological treatment plant, RO system) to achieve Zero Liquid Discharge system.

This will eliminate effluent leakage to surrounding area of the plant.

7. Aspect: Improper Storage of Flammable chemicals Methanol, Toluene, Acetone

causing leakage of flammable chemical.

Impact: presence of ignition source caches fire, risk to plant personnel due to

thermal radiation, release of CO, CO2, toxic gases in to atmosphere and global

warming.

Mitigation measure: Each solvent storage tank will have dyke to contain entire

contents. This will avoid leakage of solvent to the outside of dyke wall. The tanks

will be monitored regularly for any corrosion at valve joints, valve gland leakages.

The storage tanks will have fire alarm system. In case if it is catches fire, it will be

extinguished with DCP, fire extinguishers and fire hydrant water. This will

minimize the thermal radiation and release of CO, CO2 and toxic gases to the

atmosphere.

8. Aspect: ground water extraction for industry

Impact: Depletion of water resources

Mitigation measure: The industry will conserve rain water by adopting rain water

harvesting system in the plant of 7054 m3/ annum.



2.19 ASSESSMENT OF NEW & UNTESTED TECHNOLOGY FOR RISK OF

TECHNOLOGICAL FAILURE

No new or untested technology will be used in the proposed project but the

manufacturing process may be altered for better yields after successful lab tests and

R&D.

DESCRIPTION OF THE

ENVIRONMENT

CHAPTER -III


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter – III Page 122

CHAPTER-III

DESCRIPTION OF THE ENVIRONMENT

3.0 INTRODUCTION

Baseline data generation is a part of the Environmental Impact Assessment study, which

helps to evaluate the predicted impacts on the various environmental attributes in the study

area by using scientifically developed and widely accepted environmental impact

assessment methodologies. This further helps in preparing an Environment Management

Plan (EMP) outlining the measures for improving the environmental quality and scope for

future improvements for environmentally sustainable development. The baseline

environmental study also helps to identify the critical environmental attributes, which are

required to be monitored after implementation of the project.

This chapter illustrates the description of the existing environmental status of the study

area with reference to the prominent environmental attributes. The existing environmental

setting is considered to adjudge the baseline conditions which are described with respect

to climate, hydro-geological aspects, atmospheric conditions, water quality, soil quality,

vegetation pattern, ecology, socio-economic profile, landuse, places of archaeological

importance etc.

3.1 STUDY AREA

SGR Laboratories Pvt. Ltd. proposed manufacturing unit is located at Sy No: 290 &

Parts, Dondapadu (V), Chinthalapalem (M), Suryapet District, Telangana State.

3.1.2 Study Period

The baseline data was collected for the study area during the period of October to

December – 2018.

3.2 Geological & Hydrogeological Environment

Scope and Methodology

In any given environment the occurrence and movement of ground water and its quality

and quantity is chiefly controlled and governed by many factors such as geographical set-

up, climate and rainfall conditions, hydrological features, topography, soil characteristics,

the nature and thickness of underlying rock formations and other related aspects that

prevail in an area. Therefore the study envisages indentifying the existing ground water

conditions comprising both quality and potential within the project site and its



neighborhood, relating the projected utilization for the production, identifying the likely

impacts on surface and ground water resources and indicating mitigation measures. In

order to accomplish the proposed objective of the study, the scope and methodology

adopted is as follows:

Collection of the relevant data contained in the EIA and EMP Reports, from the

reports and maps of Central Ground Water Board (CGWB), Geological Survey of

India (GSI) and Indian Meterological Department (IMD) other Institutions and

Departments.

Identify Inter- related and Inter – dependent key factors that play vital role in the

occurrence of ground water its quality and potential.

Identify surface water resources in the project site and its catchment area.

Assess the ground water resource potential in the catchment area of the project

site.

The field investigations were carried out to study surface rock outcrops, geological cross

sections in the road cuttings. Inventory of wells representing the entire watershed area was

carried out. Hydrogeological data of about 10 wells was collected. Water levels were

measured in the Dug wells and bore wells.

Information already available and the data collected during the survey is collated and

analyzed to comprehend the overall ground water situation in the area. An attempt is made

to predict the likely changes that could occur on account of the proposed bulk drugs

manufacturing and certain mitigation measures have been indicated to avoid adverse

effect on the ground water environment.

3.2.1 Geomorphology and Soil Types:

The domal (radial) structures are reflected in the geomorphology of the region as elevated

circular drainage pattern of the region from which the disposition and various

geomorphological units are identified. The soil comprises of red soil, black soil, alkaline soil

and alluvium. The red soil constitutes 85 % of the area. Black soil is found over the

limestone area, in the southeastern part of the area. Alkaline soil occurs as limited patches

in the central part. Alluvial soil occurs along Alair, Musi and Kargal rivers.



3.2.2 Geology

The district is underlain by variety of geological formations comprising from the oldest

Archaeans to Recent Alluvium. Hydrogeologically these formations are classified as

consolidated (Hard), semi-consolidated (Soft) and unconsolidated (Soft) formations. The

consolidated formations include crystallines (khondalites, charnockites and granitic

gneisses) and metasediments (Limestones, shales, phyllites and quartzites) of Archaean

and Pre-cambrian periods respectively.

3.2.3 Hydrogeology

The proposed Bulk Drug Manufacturing unit is located on the upper reaches of the

catchment and is over the run off zone. A Third order stream is passing over the

northeastern portion of the proposed Project area draining south east. The catchment area

of the proposed site is moderate and recharge conditions are good. However, the buffer

zone of 10Kms radius has good catchment, excellentand favorable rechargeconditions

with streams and tanks of considerable storage potential.

All the stream courses are ephemeral in character and carry large volumes of storm flows

during rainy season and remain dry during non - monsoon season. The width of the

streams is narrow and follows the weak planes within the hard rock formations. A drainage

map of the area around the proposed plant is annexed.A drainage map of the area around

the project is shown in Figure 3.1.

3.2.4 Groundwater Conditions

Groundwater occurs under semi-confined conditions in the bedding planes of limestone

and limited in the weathered zones. Eleven bore wells were inventoried to assess the

groundwater conditions. The depth to water levels was found to be 70-120m. The yield

ranges of bore wells were found to be 80-150 lpm. The quality of water is found to be

potable.

As the extent of the proposed site is very small only roof top rainwater harvesting is

suggested for improving the recharge to the groundwater.

The proposed area is categorized as safe by the Groundwater department and scope for

development & stage of groundwater is good. The site is feasible for groundwater

extraction for the proposed Bulk drugs & intermediates manufacturing unit.



3.2.5 Drainage Pattern of Study Area

Dendritic drainage indicates homogenous rocks, the trellis, rectangular and parallel

drainage patterns indicate structural and lithological controls. The coarse drainage texture

indicates highly porous and permeable rock formations; whereas fine drainage texture is

more common in less pervious formations. Weathering profile controls of ground water and

above all discharge of surface water along the major streams and rivers. Fractured pattern

and other structural features control drainage pattern in hard rocks. Slope / gradient of

area coupled with drainage density decide the weathering profile. These two factors

synthesized with rainfall (of a given area) provide information on the ground water potential

(weathering profile, structural factors) and discharge of surface water along streams.

Weathering profile increases groundwater potential, slope/gradient together with runoff

controls the thickness of weathered zone. Major faults, lineaments sometimes connects

two are more watersheds (Drainage Basins) and act as conduits (Interconnecting channel

ways). Flow of groundwater along these week zones is an established fact. A proper

understanding of the major faults, their influence of groundwater flow has to be understood

from drainage system and its controls. The study of the drainage for the present purpose is

to understand that, to what extent the ground water would be affected by the water

pollutants. Survey of India Topomaps, satellite data of summer season are the main input

data for preparation of drainage map. The drainage map is prepared using Toposheets of

Survey of India on 1:50,000 scale and updated using latest satellite data wherever

deviations and new developments are observed.

Step I: All the rivers its tributaries and drainage network shown on the Toposheets are

captured. The boundaries of all rivers/water bodies with names appearing are captured

from Toposheets. The drainage is drawn from whole to part, i.e., from the rivers to

tributaries to first drains to second order drains to third order drains.

Step II: Based on the post monsoon satellite image extent of water spread and dry parts

are updated. The water bodies which did not exist at the time of survey of Toposheets, if

any are also captured based on satellite imagery. The study area forms part of Mahanadi

river basin the southern of the area from western part, towards East. All these rivers and

rivulets get dry for major part of the year and carry heavy floods during rainy season. The

drainage map of study area has showing in figure 3.1.



Table 3.1

Showing drainage density based criteria by smith and strahler.

Drainage Density

Texture Runoff Infiltration Relief Stratum

< 5.0 Coarse (High) High Low High High Impermeable

5.0 - 13.7 Medium Medium Medium Medium Medium Permeable

13.7 - 155.3 Ultra fine (Low) Low High Low Good Permeable

Table 3.2

Showing drainage density based criteria proposed by Long Bein

Drainage Density Areas Runoff

0.55 - 2.09 Steep Impervious Areas High

1.03 Humid Regions High

Table 3.3

Showing Drainage Density Based Criteria Proposed by Horton

Drainage Density Stratum Runoff

0.9 - 1.29 Steep Impervious Areas High

< 0.9 Permeable High Infiltration Areas Low

3.2.6 Drainage Map

This Draingae map consists of all water bodies, rivers, tributaries, perennial & ephemeral

streams, reservoirs, tanks, ponds and the entire drainage network from first order

originating in the area to the last order joining the rivers, tributaries and tanks based on

topography. Understanding the importance of drainage depends on the purpose and the

objective of the project. For the present study purpose the following factors have to be

understood and extracted from the study of the drainage pattern. Drainage network helps

in delineation of watersheds. Drainage density and type of drainage gives information

related to runoff, infiltration relief and permeability.



FIGURE 3.1 SHOWING DRAINAGE MAP OF THE PROJECT STUDY AREA



3.3 Micrometeorology and Climate

The meteorological data recorded during the study period is very useful for proper

interpretation of the baseline information as well as for input to prediction models for

air quality dispersion. Historical data on meteorological parameters will also play an

important role in identifying general meteorological regime of the region.

Automatic weather station was installed in the project site at about 10 m above the

ground level. On-site monitoring was undertaken for various meteorological variables

in order to record the site-specific data. Data was recorded every hour continuously

from Oct – 2018 to Dec – 2018.

The critical weather elements that influence air pollution are wind speed, wind

direction, temperature, which together determines atmosphere stability. The details

of the temperature, relative humidity and rainfall observed during study period (Oct –

2018 to Dec – 2018) are given below.

A. Temperature:

During the study period the minimum and maximum temperatures were recorded as

12 °C and 39 °C respectively.

B. Relative Humidity:

During study period at project site, the relative humidity was recorded as 79%

C. Rainfall

Rainfall during the Study Period at the Project Site is 28.2 mm. Normal annual

rainfall is 982 mm. (Source: IMD Climatatological Normals, Nandigama 1981 - 2010)

D. Wind pattern

Dispersion of different air pollutants released into the atmosphere has significant

impacts on neighborhood air environment. The dispersion/dilution of the released

pollutant over a large area will result in considerable reduction of the concentration of

a pollutant. The dispersion in turn depends on the weather conditions like the wind

speed, wind direction, temperature, relative humidity, mixing height, cloud cover and

also the rainfall in the area.

Wind speed and direction data recorded during the study period is useful in

identifying the influence of meteorology on the air quality of the area. Wind roses on

sixteen sector basis have been drawn. Wind directions and wind speed frequency



observed during study period is given in Table 3.4 and wind rose diagrams are

given in Figure 3.2.

The following observations can be made from the collected data;

Calm period is observed to be 1.9 % during the time of monitoring.

The predominant wind direction is N & NE.

Other than predominant wind directions wind was blowing in North direction.

Average wind speed 3.5 m/s.

Mostly the wind speeds are observed to be in the range of 5.7 – 8.8 m/sec,

0.5 – 2.1 m/Sec, 3.6 - 5.7 m/Sec, with frequency of distribution percentages

ranges from 27.5, 21.1, & 16.2.



TABLE 3.4: FREQUENCY DISTRIBUTION WIND DIRECTIONS AND WIND SPEED

S. No Wind Directions Wind Classes (m/s)

0.5 - 2.1 2.1 - 3.6 3.6 - 5.7 5.7 - 8.8 8.8 - 11.1 >= 11.1 Total (%)

1 N 348.75 - 11.25 4.4 9.6 1.9 0.3 0 0 16.2

2 NNE 11.25 - 33.75 3.6 4.8 4.3 0.5 0 0 13.2

3 NE 33.75 - 56.25 4.2 4.3 5 0.6 0 0 14.1

4 ENE 56.25 - 78.75 3.4 3.7 2.9 0.1 0 0 10.1

5 E 78.75 - 101.25 3.1 2.6 2 0.2 0 0 7.9

6 ESE 101.25 - 123.75 2.9 2.7 0.7 0 0 0 6.3

7 SE 123.75 - 146.25 3.2 2.7 0.8 0 0 0 6.7

8 SSE 146.25 - 168.75 2.4 2.1 0.6 0 0 0 5.1

9 S 168.75 - 191.25 0.6 0.8 0.1 0.1 0 0 1.6

10 SSW 191.25 - 213.75 1 0.4 0 0 0 0 1.4

11 SW 213.75 - 236.25 0.8 0.1 0 0 0 0 0.9

12 WSW 236.25 - 258.75 0.9 0.4 0 0 0 0 1.3

13 W 258.75 - 281.25 1.1 0.2 0.3 0 0 0 1.6

14 WNW 281.25 - 303.75 1.5 0.5 0.5 0 0 0 2.5

15 NW 303.75 - 326.25 1.7 0.8 0 0 0 0 2.5

16 NNW 326.25 - 348.75 3.2 3.2 0.3 0 0 0 6.7

Sub-Total 38 38.9 19.4 1.8 0 0 98.1

Calms 1.9

Missing/Incomplete 0

Total 100



FIGURE 3.2: WINDROSE DIAGRAM PERIOD: OCT 2018 – DEC 2018

FIGURE 3.3: WINDROSE DIAGRAM FOR SECONDARY DATA



Table 3.5: Comparison of Primary Data (PROJECT SITE) with Secondary Data

(IMD DATA)

Month Parameter Primary Data Secondary Data

October Predominant wind direction

N & NE N, NW & NE

November N & NE N, NW & NE

December N & NE N, NW & NE

IMD DATA

30 years meteorological data for Peddapuram for the period of 1981 to 2010 is

collected from nearby IMD station (Kakinada) for Wind speed (kmph), Wind direction

(0 to 3600), Ambient Temperature (0C), Relative humidity (%), Rainfall (mm) and

Mixing height (m) collected from ATLAS.

Table 3.6: IMD Data for Chinthalapalem, Nandigama IMD Station

Month

Temperature, (0C)

Relative Humidity, (%)

Wind Speed (kmph)

Monthly Avg.

Rainfall (mm)

Predominant Wind

Direction coming from

Max Min Max Min

January 33.4 13.6 84 49 4.6 11.8 SE, N, S &

NW

February 36.6 15.6 81 44 5.3 7.7 SE, S & SW

March 39.8 18.2 78 39 7.0 14.1 SE, S & SW

April 42.4 21.1 72 39 8.0 13.9 SE, S & SW

May 44.7 21.8 62 36 8.1 46.2 SE, S, SW &

NW

June 42.4 22.0 67 49 7.0 117 SW, W & NW

July 38.1 21.8 75 62 6.4 179.8 SW, W & NW

August 36.1 21.9 79 68 5.5 225.9 SW, W & NW

September 35.8 21.6 82 70 4.2 188.7 SW, W & NW

October 34.8 19.7 83 71 4.4 138.3 N, NW & NE

November 33.2 15.3 81 64 4.9 28.2 N, NW & NE

December 32.2 13.6 82 56 4.2 10.4 N, NW & NE

Source: IMD data collected from IMD Nandigama for 1981 to 2010 (30 years)



3.4 AIR ENVIRONMENT

The ambient air quality with respect to the study area of 10 km radius around the

plant site forms the baseline information. The various sources of air pollution in the

region are industrial, traffic and rural activities. This will also be useful for assessing

the conformity to standards of the ambient air quality during the plant operation. The

study area represents mostly rural environment.

The baseline status of the ambient air quality has been assessed through a

scientifically designed ambient air quality monitoring network. The design of

monitoring network in the air quality surveillance programme has been based on the

following considerations:

Meteorological conditions on synoptic scale.

Topography of the study area.

Representation of plant site.

Influence of the existing sources (if any) are to be kept at minimum.

Inclusion of major distinct villages to collect the baseline status.

Representation of down wind direction.

Representation of upwind direction.

Representation of cross sectional distribution in the down wind direction.

The ambient air quality monitoring was carried out in accordance with National

Ambient Air Quality Standards (NAAQS) of CPCB. Ambient Air Quality Monitoring

(AAQM) was carried out at eight locations for 2 days per week for 12 weeks during

study period and the locations are shown in Figure 3.4. The locations of the different

stations with respect to its distance and direction from project site are shown in

Table 3.7.



TABLE 3.7: AMBIENT AIR QUALITY SAMPLING LOCATIONS

S.No. Code Name of Sampling Location Distance (km) w.r.t Project

Direction w.r.t Project

1 A1 Project Site -- --

2 A2 Dondapadu (near Sitapurm Colony)

1.4 WSW

3 A3 Mukteshwarapuram 2.6 E

4 A4 Bugga Madharam 2.2 SE

5 A5 Vajinepalli 3.7 SSE

6 A6 Ramapuram 5.7 WNW

7 A7 Budavada 5.6 NNW

8 A8 Jaggayyapeta 7.9 N

The monitoring was carried out for a three month period (Oct 2018 – Dec 2018) at a

frequency of twice a week at each station adopting a continuous 24- hour schedule.

The following parameters were monitored in the study area :

Particulate Matter (PM10)

Particulate Matter (PM2.5)

Sulphur Dioxide (SO2)

Oxides of Nitrogen (NOx)

Carbon Monoxide (CO)

Ammonia (NH3)

Volitail Organic Compounds (VOC)



FIGURE 3.4: AMBIENT AIR QUALITY SAMPLING LOCATIONS MAP



3.4.1. National Ambient Air Quality Standards (NAAQS)

National Ambient Air Quality Standards, 2009 for the notified Industrial, Residential,

Rural and Other Areas as well as Sensitive Areas are presented in table below. The

state has not promulgated separate Ambient Air Quality Standards.

TABLE 3.8: NATIONAL AMBIENT AIR QUALITY STANDARDS

S. No

Pollutant Time

Weighted Average

Concentration in Ambient Air

Methods of measurement

Industrial Area

Residential, Rural &

other Areas

Ecologically sensitive area

(Notified by Central Govt)

1 Sulphur Dioxide (SO2) µg/m3

Annual * 50 20 -Improved West and Gaeke method -Ultraviolet fluorescence

24 hours** 80 80

2 Oxides of Nitrogen as NO2 µg/m3

Annual * 40 30 -Modified Jocob and Hochheise(NaArsenite ) -Chemiluminescence

24 hours** 80 80

3 Particulate matter (size Less than 10µm) µg/m3

Annual * 60 60 -Gravimetric -TOEM -Beta attenuation

24 hours** 100 100

4 Particulate matter (size less than 2.5 µm) µg/m3

Annual * 40 40 -Gravimetric -TOEM -Beta attenuation

24 hours** 60 60

5 Ozone µg/m3

8 hours** 100 100 - UV Photometric -Chemiluminescence -Chemical method

1 hour** 180 180

6 Lead (Pb)

µg/m3

Annual * 0.50 0.50 -AAS/ICP method for sampling on EPM 2000 or Equivalent Filter paper -ED -XRF using Teflon filter paper

24 hours** 1.0 1.0

7 Carbon

Monooxide mg/m3

8 hours**

02 02 -Non Dispersive Infra Red (NDIR) spectroscopy 1 hour ** 04 04

8 Ammonia (NH3) µg/m3

Annual * 100 100 -Chemiluminescence -Indo-Phenol Blue method

24 hours** 400 400

9 Benzene µg/m3 Annual * 05 05

-GC based continuous analyzer - Adsorption & desorption followed by GC analysis

10 Benzo(a) pyrene (BaP)- Particulate Phase only ng/m3

Annual * 01 01 -Solvent extraction followed by GC/HPLC extraction

11 Arsenic ng/m3 Annual * 06 06

AAS/ICP method for sampling on EPM2000 OR Equivalent Filter paper

12 Nickel ng/m3 Annual *

20 20 -AAS/ICP method for sampling on EPM2000



S. No

Pollutant Time

Weighted Average

Concentration in Ambient Air

Methods of measurement

Industrial Area

Residential, Rural &

other Areas

Ecologically sensitive area

(Notified by Central Govt)

OR Equivalent Filter paper

G.S.No.826 (E) dated 16th November, 2009. Vide letter no. F. No. Q-15017/43/2007-CPW.

*Average Arithmetic mean of minimum 104 measurements in a year taken for a week

24 hourly at uniform interval.

**24 hourly/8 hourly values should meet 98 percent of the time in a year.

TABLE 3.9: AMBIENT AIR QUALITY RESULTS FOR PM10

Location Minimum Maximum 98th

Percentile NAAQ

Standards

Project Site 59.1 66.3 66.3 100

Jaggayyapeta 57.2 62.0 61.8 100

Mukteshwarapuram 52.9 58.9 58.7 100

Bugga Madharam 53.4 60.2 59.7 100

Vajinepalli 45.6 65.8 65.5 100

Ramapuram 47.3 61.9 61.5 100

Budavada 38.1 55.0 55.0 100

Dondapadu (near Sitapuram) 58.2 69.6 69.3 100

FIGURE 3.5: AMBIENT AIR QUALITY RESULTS FOR PM10

020406080

100

PM

10

µg/

m3

Air Quality Monitoring Locations

Minimum

Average

98 Percentile

CPCB Norms



TABLE 3.10: AMBIENT AIR QUALITY RESULTS FOR PM2.5


Percentile NAAQ

Standards

Project Site 23.7 26.5 26.5 60

Jaggayyapeta 22.9 24.8 24.7 60


Bugga Madharam 21.4 24.1 23.9 60

Vajinepalli 18.2 26.3 26.2 60

Ramapuram 18.9 24.8 24.6 60

Budavada 15.2 22.0 22.0 60


FIGURE 3.6: AMBIENT AIR QUALITY RESULTS FOR PM2.5

TABLE 3.11: AMBIENT AIR QUALITY RESULTS FOR SO2


Percentile NAAQ

Standards

Project Site 13.1 14.7 14.7 80




Vajinepalli 10.1 14.6 14.6 80

Ramapuram 10.5 13.8 13.7 80

Budavada 8.5 12.2 12.2 80


010203040506070

PM

2.5

µg/

m3


Minimum

Average

98 Percentile

CPCB Norms



FIGURE 3.7: AMBIENT AIR QUALITY RESULTS FOR SO2

TABLE 3.12: AMBIENT AIR QUALITY RESULTS FOR NOX


Percentile NAAQ

Standards

Project Site 20.5 22.1 22.1 80




Vajinepalli 17.5 22.0 22.0 80

Ramapuram 17.9 21.2 21.1 80

Budavada 15.9 19.6 19.6 80


FIGURE 3.8: AMBIENT AIR QUALITY RESULTS FOR NOX

0102030405060708090

SO2

µg/

m3


Minimum

Average

98 Percentile

CPCB Norms

0102030405060708090

NO

Xµ

g/m

3


Minimum

Average

98 Percentile

CPCB Norms



TABLE 3.13: AMBIENT AIR QUALITY RESULTS FOR CO


Percentile NAAQ

Standards

Project Site 0.66 0.87 0.87 2

Dondapadu (near Sitapurm) 0.21 0.58 0.57 2



Vajinepalli 0.12 0.54 0.45 2

Ramapuram 0.12 0.36 0.35 2

Budavada 0.12 0.47 0.46 2


FIGURE 3.9: AMBIENT AIR QUALITY RESULTS FOR CO

TABLE 3.14: AMBIENT AIR QUALITY RESULTS FOR NH3


Percentile NAAQ

Standards

Project Site 25.8 27.4 27.4 400

Jaggayyapeta 25.4 26.5 26.4 400


Bugga Madharam 24.6 26.1 26.0 400

Vajinepalli 22.8 27.3 27.3 400

Ramapuram 23.2 26.5 26.4 400

Budavada 21.2 24.9 24.9 400

Dondapadu (near Sitapurm) 25.6 28.2 28.1 400

012345

CO

mg/

m3


Minimum

Average

98 Percentile

CPCB Norms



FIGURE 3.10: AMBIENT AIR QUALITY RESULTS FOR NH3

050

100150200250300350400

Ammonia µg/m3

Minimum

Average

98 Percentile

CPCB Norms



3.4.2. Ambient Air Quality Data (AAQ)

The Maximum, Minimum & 98th percentile values for all the sampling are shown in

Table 3.7. The location wise monitored Ambient Air Quality details are presented in

Table 3.8 to Table 3.15.

1. Particulate Matter (PM10)

The maximum and minimum concentrations for PM10 were recorded in the study

area showed 98th percentile values in the range of 55.0 – 69.3 μg/ m3. The

maximum concentration 69.3 μg/ m3 were recorded at sampling locations at

Dondapadu (near Sitapurm). The concentrations of PM10 are well below the

CPCB standard of 100 μg/ m3.

2. Particulate Matter (PM2.5)

The CPCB Standard for concentration of PM2.5 is 60 μg/ m3. The maximum and

minimum 98th percentile concentrations for Particulate Matter (PM2.5) monitored

in the study area were 22.0 – 27.7 μg/m3 respectively. Highest value of 27.7 μg/

m3 was at Dondapadu (near Sitapurm). The concentration of PM2.5 is well below

the prescribed limit of 60 μg/ m3

3. Sulphur Dioxide (SO2)

98th percentile value of Sulphur dioxide in the study area from the monitored data

was in the range of 12.2 – 15.4 μg/ m3. Maximum value of Sulpur dioxide of 15.4

μg/ m3 obtained at Dondapadu (near Sitapurm). The concentration of SO2 is well


4. Oxides of Nitrogen (NOx)

Ambient air quality status monitored for oxides of nitrogen in the study area were

in the range with 98th percentile values between 19.6 – 22.8 μg/ m3. A maximum

value of 22.8 μg/ m3 was prevailing at the time of sampling at Dondapadu (near

Sitapurm). The concentration of NOX is well below the prescribed limit of 80 μg/

m3

5. Carbon Monoxide (CO)

The maximum and minimum 98th percentile concentrations for Carbon Monoxide

(CO) monitored in the study area were 0.35 – 0.87 mg/m3 respectively. Highest



value of 0.87 mg/ m3 was at the Project Site. The concentration of CO is well

below the prescribed limit of 2 mg/ m3

6. Ammonia (NH3)

The maximum and minimum 98th percentile concentrations for Ammonia (NH3)

monitored in the study area were 24.9 – 28.1 μg/m3 respectively. Highest value of

28.1 μg/ m3 was at Dondapadu (near Sitapurm). The concentration of NH3 is well


7. Volatile Organic Compounds (VOCs)

Volatile Organic Compounds (VOCs) concentration in study area was found to be

Below Detectable Limit of 1 ppm.

The ambient air quality monitoring results indicates that the overall air quality in the

study area is within permissible standards prescribed by NAAQ Standards.



TABLE 3.15: THE MAXIMUM, MINIMUM & 98th PERCENTILE VALUES FOR ALL THE

AMBIENT AIR SAMPLING LOCATIONS

Code Name of Sampling Location

PM 10(µg/M3) PM 2.5(µg/M

3) SO2(µg/M

3) NOX(µg/M

3) CO (mg/M

3) NH3 (µg/M

3)

Min Max 98th

Min Max 98th

Min Max 98th

Min Max 98th

Min Max 98th

Min Max 98th

A1 Project Site 59.1 66.3 66.3 23.7 26.5 26.5 13.1 14.7 14.7 20.5 22.1 22.1 0.66 0.87 0.87 25.8 27.4 27.4

A2 Dondapadu (near Sitapurm Colony)

58.2 69.6 69.3 23.3 27.8 27.7 12.9 15.5 15.4 20.3 22.9 22.8 0.21 0.58 0.57 25.6 28.2 28.1

A3 Mukteshwarapuram 52.9 58.9 58.7 21.2 23.6 23.5 11.8 13.1 13.0 19.2 20.5 20.4 0.11 0.51 0.44 24.5 25.8 25.7

A4 Bugga Madharam 53.4 60.2 59.7 21.4 24.1 23.9 11.9 13.4 13.3 19.3 20.8 20.7 0.12 0.36 0.35 24.6 26.1 26.0

A5 Vajinepalli 45.6 65.8 65.5 18.2 26.3 26.2 10.1 14.6 14.6 17.5 22.0 22.0 0.12 0.54 0.45 22.8 27.3 27.3

A6 Ramapuram 47.3 61.9 61.5 18.9 24.8 24.6 10.5 13.8 13.7 17.9 21.2 21.1 0.12 0.36 0.35 23.2 26.5 26.4

A7 Budavada 38.1 55.0 55.0 15.2 22.0 22.0 8.5 12.2 12.2 15.9 19.6 19.6 0.12 0.47 0.46 21.2 24.9 24.9

A8 Jaggayyapeta 57.2 62.0 61.8 22.9 24.8 24.7 12.7 13.8 13.7 20.1 21.2 21.1 0.12 0.36 0.36 25.4 26.5 26.4

NAAQ Standards’ 100 60 80 80 2 400



3.5 WATER ENVIRONMENT

Water sampling and subsequent analysis were carried out to determine both the

groundwater and surface water quality of the study area.

Selected water quality parameters of ground water resources and surface water

resources within 10 km radius of the study area has been studied for assessing the

quality of water.

3.5.1 Methodology for Water Quality Monitoring

Ground water sources and surface water sources covering 10 km radial distance

were examined for physico-chemical, heavy metals and bacteriological parameters

in order to assess the effect of industrial and other activities on ground water and

surface water. The samples were analyzed as per the procedures specified in

'Standard Methods for the Examination of Water and Wastewater' published by

American Public Health Association (APHA).

Samples for chemical analysis were collected in polyethylene carboys. Samples for

bacteriological analysis were collected in sterilized glass bottles. Selected

physicochemical and bacteriological parameters have been analyzed for projecting

the existing water quality status in the study area. Parameters like pH and

temperature were analyzed at the time of sample collection.

The details of surface and ground water sampling locations are given in Table 3.16

and sampling locations of ground water quality and surface quality monitoring are

shown in Figure 3.11. The physico - chemical characteristics of the ground water

samples and surface water samples are presented in the Tables 3.17 & Tables 3.18.



TABLE 3.16: GROUND AND SURFACE WATER SAMPLING LOCATIONS

S.No. Code Name of Sampling Location Distance (km) w.r.t Project


Ground Water Sampling Locations

1 GW1 Near Project Site -- --

2 GW2 Mukteshwarapuram 2.6 E

3 GW3 Bugga Madharam 2.2 SE

4 GW4 Vajinepalli 3.7 SSE

5 GW5 Dondapadu 1.4 WSW

6 GW6 Ramapuram 5.7 WNW

7 GW7 Budavada 5.6 NNW

8 GW8 Kautavari Agraharam 6.5 NE

Surface Water Sampling Locations

1 SW1 Krishna River Near Muktyala (Sri Bhavani Muktheswara Swamy Vari Ghat)

2.8 ESE

2 SW2 Krishna River Near Vajinepalli 4.4 SSE

3 SW3 Palleru River near Kautavari Agraharam

7.2 NE

4 SW4 Palleru River near Budavada 5.8 NNW

5 SW5 Water body Near Jaggayyapeta

8.6 NE

6 SW6 Water body near Ramapuram 8.0 WNW

7 SW7 Mine Pit Near Ramapuram 5.2 WNW

8 SW8 Water body near Tripuravaram 9.7 NNE



FIGURE 3.11: GROUND & SURFACE WATER SAMPLING LOCATIONS MAP



TABLE 3.17 GROUNDWATER QUALITY IN THE STUDY AREA

S. No Parameter Method Unit GW1 GW2 GW3 GW4 IS 10,500 Limits

Acceptable Permissible

1 pH APHA 22nd Edition 4500 H+ B -- 7.30 7.66 7.04 7.37 6.5-8.5 No Relaxation

2 Color APHA 22nd Edition 2120 B CU < 1.0 < 1.0 < 1.0 <1.0 5 15

3 Total Dissolved Solids APHA 22nd Edition 2540 C mg/l 642 940 610 966 500 2000

4 Total Alkalinity (as CaCO3)

APHA 22nd Edition 2320 B mg/l 280 450 285 370 200 600

5 Total Hardness (as CaCO3)

APHA 22nd Edition 2340 C mg/l 405 445 375 515 200 600

6 Calcium (as Ca ) APHA 22nd Edition 3500 Ca B mg/l 118.2 84.2 150.3 158 75 200

7 Magnesium (as Mg) APHA 22nd Edition 3500-Mg B mg/l 26.7 57.1 -- 29.2 30 100

8 Sulphate (as SO4) APHA 22nd Edition 4500 SO4 E mg/l 74.0 71.2 66.5 97.3 200 400

9 Chloride (as Cl) APHA 22nd Edition 4500 Cl- B mg/l 154.9 102.9 257.4 199.9 250 1000

10 Lead as Pb APHA 22nd Edition 3111B mg/l < 0.01 < 0.01 < 0.01 < 0.01 0.01 No Relaxation

11 Cadmium as Cd APHA 22nd Edition 3111B mg/l <0.01 < 0.01 < 0.01 < 0.01 0.003 No Relaxation

12 Total Chromium as Cr APHA 22nd Edition 3111B mg/l <0.05 < 0.05 < 0.05 < 0.05 0.05 No Relaxation

13 Copper as Cu APHA 22nd Edition 3111B mg/l < 0.01 < 0.01 < 0.01 < 0.01 0.05 1.5

14 Zinc as Zn APHA 22nd Edition 3111B mg/l < 0.5 < 0.5 < 0.5 < 0.5 5 15

15 Nickel as Ni APHA 22nd Edition 3111B mg/l <0.01 < 0.01 < 0.01 < 0.01 0.02 No Relaxation

16 Fluorides as F APHA 22nd Edition 4500 F- D mg/l 6.2 5.7 1.2 1.1 1 1.5

17 Aluminium as Al APHA 22nd Edition 3500 Al B mg/l <0.03 < 0.03 < 0.03 < 0.03 0.03 0.2

18 Boron as B APHA 22nd Edition 4500 B B mg/l <0.2 <0.2 <0.2 <0.2 0.5 1

19 Manganese as Mn APHA 22nd Edition 3111B mg/l <0.02 <0.02 < 0.02 < 0.02 0.1 0.3

20 Iron as Fe APHA 22nd Edition 3500 Fe B mg/l < 0.05 < 0.05 < 0.05 < 0.05 0.3 No Relaxation

21 Nitrate Nitrogen APHA 22nd Edition 4500 NO3 B mg/l 4.2 4.6 4.5 4.0 45 No Relaxation

22 Sodium as Na APHA 22nd Edition 3500 Na B mg/l 148 95 220 185 -- --

23 Potassium as K APHA 22nd Edition 3500 K B mg/l < 5.0 <5.0 < 5.0 <5.0 -- --

24 Odour APHA 22nd Edition 2150 B -- Agreeable Agreeable Agreeable Agreeable -- --

25 Electrical Conductivity APHA 22nd Edition 2510 B μmho/cm 1060 1565 1016 1609 -- --

26 Phosphorus as P APHA 22nd Edition 4500 P C mg/l 0.18 0.82 0.920 0.75 -- --



TABLE 3.17 GROUND WATER QUALITY IN THE STUDY AREA

S. No Parameter Method Unit GW5 GW6 GW7 GW8 IS 10,500 Limits

Acceptable Permissible

1 pH APHA 22nd Edition 4500 H+ B -- 7.32 7.60 7.08 7.31 6.5-8.5 No

Relaxation

2 Color APHA 22nd Edition 2120 B CU < 1.0 < 1.0 < 1.0 <1.0 5 15

3 Total Dissolved Solids APHA 22nd Edition 2540 C mg/l 638 950 608 965 500 2000

4 Total Alkalinity (as CaCO3)

APHA 22nd Edition 2320 B mg/l 285 455 280 365 200 600

5 Total Hardness (as CaCO3)

APHA 22nd Edition 2340 C mg/l 355 450 295 415 200 600

6 Calcium (as Ca ) APHA 22nd Edition 3500 Ca B mg/l 98.5 104.2 124.0 140 75 200

7 Magnesium (as Mg) APHA 22nd Edition 3500-Mg B mg/l 25.0 46.1 -- 28.3 30 100

8 Sulphate (as SO4) APHA 22nd Edition 4500 SO4 E mg/l 69.2 70.2 69.0 98.6 200 400

9 Chloride (as Cl) APHA 22nd Edition 4500 Cl- B mg/l 154.2 102.2 256 190.2 250 1000

10 Lead as Pb APHA 22nd Edition 3111B mg/l < 0.01 < 0.01 < 0.01 < 0.01 0.01 No Relaxation

11 Cadmium as Cd APHA 22nd Edition 3111B mg/l <0.01 < 0.01 < 0.01 < 0.01 0.003 No Relaxation

12 Total Chromium as Cr APHA 22nd Edition 3111B mg/l <0.05 < 0.05 < 0.05 < 0.05 0.05 No Relaxation

13 Copper as Cu APHA 22nd Edition 3111B mg/l < 0.01 < 0.01 < 0.01 < 0.01 0.05 1.5

14 Zinc as Zn APHA 22nd Edition 3111B mg/l < 0.5 < 0.5 < 0.5 < 0.5 5 15

15 Nickel as Ni APHA 22nd Edition 3111B mg/l <0.01 < 0.01 < 0.01 < 0.01 0.02 No Relaxation

16 Fluorides as F APHA 22nd Edition 4500 F- D mg/l 5.2 5.1 1.8 1.4 1 1.5

17 Aluminium as Al APHA 22nd Edition 3500 Al B mg/l <0.03 < 0.03 < 0.03 < 0.03 0.03 0.2

18 Boron as B APHA 22nd Edition 4500 B B mg/l <0.2 <0.2 <0.2 <0.2 0.5 1

19 Manganese as Mn APHA 22nd Edition 3111B mg/l <0.02 <0.02 < 0.02 < 0.02 0.1 0.3

20 Iron as Fe APHA 22nd Edition 3500 Fe B mg/l < 0.05 < 0.05 < 0.05 < 0.05 0.3 No Relaxation

21 Nitrate Nitrogen APHA 22nd Edition 4500 NO3 B mg/l 4.0 4.5 4.2 4.1 45 No Relaxation

22 Sodium as Na APHA 22nd Edition 3500 Na B mg/l 148 95 220 185 -- --

23 Potassium as K APHA 22nd Edition 3500 K B mg/l < 5.0 <5.0 < 5.0 <5.0 -- --

24 Odour APHA 22nd Edition 2150 B -- Agreeable Agreeable Agreeable Agreeable -- --

25 Electrical Conductivity APHA 22nd Edition 2510 B μmho/cm

1052 1580 1010 1528 -- --

26 Phosphorus as P APHA 22nd Edition 4500 P C mg/l 0.15 0.72 0.810 0.80 -- --



TABLE 3.18 SURFACE WATER QUALITY IN THE STUDY AREA

S. No Parameter Method Unit SW1 SW2 SW3 SW4

1 pH APHA 22nd

Edition 4500 H+

B -- 8.39 8.39 7.83 7.95

2 Color APHA 22nd

Edition 2120 B CU <1.0 < 1.0 < 1.0 <1.0

3 Total Dissolved Solids APHA 22nd

Edition 2540 C mg/l 414 416 793 802

4 Total Alkalinity (as CaCO3) APHA 22nd

Edition 2320 B mg/l 160 180 290 310

5 Total Hardness (as CaCO3) APHA 22nd

Edition 2340 C mg/l 190 200 495 380

6 Calcium (as Ca ) APHA 22nd

Edition 3500 Ca B mg/l 52.1 44.1 64.1 78.1

7 Magnesium (as Mg) APHA 22nd

Edition 3500-Mg B mg/l 14.6 21.9 81.4 44.9

8 Sulphate (as SO4) APHA 22nd

Edition 4500 SO4 E mg/l 71.5 77.2 84.8 72.2

9 Chloride (as Cl) APHA 22nd

Edition 4500 Cl- B mg/l 244 97 204 212

10 Lead as Pb APHA 22nd Edition 3111B mg/l < 0.01 < 0.01 < 0.01 < 0.01

11 Cadmium as Cd APHA 22nd Edition 3111B mg/l <0.01 < 0.01 < 0.01 < 0.01

12 Total Chromium as Cr APHA 22nd Edition 3111B mg/l <0.05 < 0.05 < 0.05 < 0.05

13 Copper as Cu APHA 22nd Edition 3111B mg/l < 0.01 < 0.01 < 0.01 < 0.01

14 Zinc as Zn APHA 22nd Edition 3111B mg/l < 0.5 < 0.5 < 0.5 < 0.5

15 Nickel as Ni APHA 22nd Edition 3111B mg/l <0.01 < 0.01 < 0.01 < 0.01

16 Fluorides as F APHA 22nd Edition 4500 F- D mg/l 2.6 2.8 4.5 3.3

17 Aluminium as Al APHA 22nd Edition 3500 Al B mg/l <0.03 < 0.03 < 0.03 < 0.03

18 Boron as B APHA 22nd Edition 4500 B B mg/l <0.2 <0.2 <0.2 <0.2

19 Manganese as Mn APHA 22nd Edition 3111B mg/l <0.02 <0.02 < 0.02 < 0.02

20 Iron as Fe APHA 22nd Edition 3500 Fe B mg/l < 0.05 < 0.05 < 0.05 < 0.05

21 Nitrate Nitrogen APHA 22nd

Edition 4500 NO3 B mg/l 4.2 4.4 4.6 4.8

22 Chemical Oxygen Demand APHA 22nd

Edition 5220 B mg/l 6 8 4 6

23 BOD(3day’s at 27oC) IS 3025 (Part – 44) 2009 mg/l 2.0 3.5 <2.0 2.4

24 Sodium as Na APHA 22nd

Edition 3500 Na B mg/l 212 89 189 201

25 Potassium as K APHA 22nd

Edition 3500 K B mg/l 5.0 4.2 4.1 4.6

26 Total Suspended Solids APHA 22nd

Edition 2540 D mg/l <10 <10 <10 <10

27 Dissolved Oxygen APHA 22nd

Edition 4500 O C mg/l 5.9 5.8 5.8 6.4

28 Oil and grease APHA 22nd

Edition 5520 B mg/l <5.0 <5.0 <5.0 <5.0

29 Electrical Conductivity APHA 22nd

Edition 2510 B μmho/cm 687 692 1219 1334

30 Phosphorus as P APHA 22nd

Edition 4500 P C mg/l <1.0 <1.0 <1.0 <1.0

31 Total Coliform IS 1622 MPN/100 ml 46 50 48 51

32 Feacal Coliforms IS 1622 MPN/100 ml 7 8 7 8



TABLE 3.18 SURFACE WATER QUALITY IN THE STUDY AREA

S. No Parameter Method Unit SW5 SW6 SW7 SW8

1 pH APHA 22nd Edition 4500 H+ B -- 7.74 7.47 7.42 7.90

2 Color APHA 22nd Edition 2120 B CU <1.0 < 1.0 < 1.0 <1.0

3 Total Dissolved Solids APHA 22nd Edition 2540 C mg/l 954 536 821 728

4 Total Alkalinity (as CaCO3) APHA 22nd Edition 2320 B mg/l 460 375 220 290

5 Total Hardness (as CaCO3) APHA 22nd Edition 2340 C mg/l 455 315 490 320

6 Calcium (as Ca ) APHA 22nd Edition 3500 Ca B mg/l 58.2 76.1 62 76.1

7 Magnesium (as Mg) APHA 22nd Edition 3500-Mg B mg/l 75.3 30.3 52.4 41.9

8 Sulphate (as SO4) APHA 22nd Edition 4500 SO4 E mg/l 69.1 35.4 58.8 71.2

9 Chloride (as Cl) APHA 22nd Edition 4500 Cl- B mg/l 265 62 184 210

10 Lead as Pb APHA 22nd Edition 3111B mg/l < 0.01 < 0.01 < 0.01 < 0.01

11 Cadmium as Cd APHA 22nd Edition 3111B mg/l <0.01 < 0.01 < 0.01 < 0.01

12 Total Chromium as Cr APHA 22nd Edition 3111B mg/l <0.05 < 0.05 < 0.05 < 0.05

13 Copper as Cu APHA 22nd Edition 3111B mg/l < 0.01 < 0.01 < 0.01 < 0.01

14 Zinc as Zn APHA 22nd Edition 3111B mg/l < 0.5 < 0.5 < 0.5 < 0.5

15 Nickel as Ni APHA 22nd Edition 3111B mg/l <0.01 < 0.01 < 0.01 < 0.01

16 Fluorides as F APHA 22nd Edition 4500 F- D mg/l 7.2 4.5 4.4 3.3

17 Aluminium as Al APHA 22nd Edition 3500 Al B mg/l <0.03 < 0.03 < 0.03 < 0.03

18 Boron as B APHA 22nd Edition 4500 B B mg/l <0.2 <0.2 <0.2 <0.2

19 Manganese as Mn APHA 22nd Edition 3111B mg/l <0.02 <0.02 < 0.02 < 0.02

20 Iron as Fe APHA 22nd Edition 3500 Fe B mg/l < 0.05 < 0.05 < 0.05 < 0.05

21 Nitrate Nitrogen APHA 22nd Edition 4500 NO3 B mg/l 4.6 4.5 4.9 4.8

22 Chemical Oxygen Demand APHA 22nd Edition 5220 B mg/l 8 7.4 4 4

23 BOD(3day’s at 27oC) IS 3025 (Part – 44) 2009 mg/l 3.0 2.8 <2.0 2.0

24 Sodium as Na APHA 22nd Edition 3500 Na B mg/l 225 59.2 162 188

25 Potassium as K APHA 22nd Edition 3500 K B mg/l 4.1 4.3 4.1 4.4

26 Total Suspended Solids APHA 22nd Edition 2540 D mg/l <10 <10 <10 <10

27 Dissolved Oxygen APHA 22nd Edition 4500 O C mg/l 6.2 5.8 5.0 6.0

28 Oil and grease APHA 22nd Edition 5520 B mg/l <5.0 <5.0 <5.0 <5.0

29 Electrical Conductivity APHA 22nd Edition 2510 B μmho/cm 1585 892 1180 1290

30 Phosphorus as P APHA 22nd Edition 4500 P C mg/l <1.0 <1.0 <1.0 <1.0

31 Total Coliform IS 1622 MPN/100 ml 51.0 48.0 42.0 50

32 Feacal Coliforms IS 1622 MPN/100 ml 9 8 5 5



A. Summary of Groundwater Samples within 10 Km Radius

pH of the ground water samples collected was in the range between 7.04 –

7.66. All samples are below acceptable limits. Only drinking water samples

have fixed pH limit which is 6.5 -8.5 as per IS 10500-2012.

The acceptable limits for total dissolved solids as per IS: 10500-2012 are 500

mg/l whereas the permissible limits in absence of alternate source are 2000

mg/l, beyond this palatability decreases and may cause gastro intestinal

irritation. Total dissolved solids in the ground water samples were in the range

between 608 – 966 mg/l. All samples are above acceptable limits, but all

samples are well below the permissible limits of 2000 mg/l.

In the ground water samples collected from the study area, the Total hardness

was found to vary between 295 – 515 mg/l. All samples are above acceptable

limits and seven ground water samples for Total hardness are above

acceptable limit but within the permissible limits, while one sample is above the

permissible of 600 mg/l.

The acceptable limit for chloride is 250 mg/l as per IS: 10500 whereas the

permissible limit of the same is 1000 mg/l beyond this limit taste, corrosion and

palatability are affected. The Chlorides concentration was found to vary

between 102.2 – 257.4 mg/l. Six samples are below acceptable limits while

one sample is above acceptable limits but within permissible limits.

Fluoride is the other important parameter, which has the acceptable limit of 1

mg/l and permissible limit of 1.5 mg/l. was found to vary between 1.1 – 6.2

mg/l.

The Sulphates concentration was found to vary between 66.5 – 98.6 mg/l. All

the samples for Sulphates concentration was found are within acceptable limits

of 200 mg/l.

Ground water samples collected from eight locations within 10 km radius from the

plant site & analyzed as per standard methods of water and wastewater analysis

(APHA).

The water quality of the study area is found to be above the acceptable limits of

IS10500, for parameters TDS, Total hardness, Total Alkalinity, Calcium, Magnesium,

Fluorides.



Summary of Surface Water Samples within 10 km Radius:

pH of the water samples collected was in the range between 7.42 – 8.39.

Total dissolved solids in the samples were in the range between 414 – 954 mg/l.

Total hardness was found to be in the range of 190 – 495 mg/l.

Chlorides concentration was found to vary between 62 – 265 mg/l.

Fluoride concentration was found to vary between 2.6 – 7.2 mg/l.

Sulphates concentration was found to vary between 35.4 –84.8 mg/l.

3.6. NOISE ENVIRONMENT

Noise, often defined as unwanted sound, interferes with speech communication,

causes annoyance, distracts from work, and disturbs sleep thus deteriorating quality

of human environment. Noise levels in the study area have therefore been

measured, at selected points, to provide the baseline data to describe the existing

situation.

Measured noise levels displayed as a function of time provides a useful scheme for

describing the acoustical climate of a community. Noise levels records at each

station with a time interval of about one hour are computed for equivalent noise

levels. Equivalent noise level is a single number descriptor for describing time

varying noise levels.

3.6.1 Noise Monitoring Stations

In order to assess the noise levels in the study area, monitoring was carried out at

eight different locations within 10 km radius of the study area. The noise monitoring

locations are shown in figure 3.12 and distances & directions of monitoring location

mentioned in Table 3.19. Noise levels were recorded and computed for equivalent

noise levels for day-equivalent, night-equivalent & day-night equivalent.

Sound Pressure Levels (SPL) measurements were recorded at eight locations. The

readings were taken for every hour for 24-hrs. The day noise levels have been

monitored during 6 am to 10 pm and night noise levels during 10 pm to 6 am at all

the locations covered in the study area.

The noise recording stations and the summary of the minimum, maximum, day -



equivalent, night - equivalent and day-night equivalent values computed for various

location in the study area is given in Table 3.20.

TABLE 3.19: NOISE MONITORING LOCATIONS

S No. Code Name of Sampling

Location Distance (km) w.r.t Project


1. N1 Project Site -- --

2. N2 Dondapadu 1.4 WSW

3. N3 Mukteshwarapuram 2.6 E

4. N4 Bugga Madharam 2.2 SE

5. N5 Vajinepalli 3.7 SSE

6. N6 Ramapuram 5.7 WNW

7. N7 Budavada 5.6 NNW

8. N8 Jaggayyahpet 7.9 N



FIGURE 3.12: NOISE SAMPLING LOCATIONS MAP



TABLE 3.20: AMBIENT NOISE LEVELS WITHIN STUDY AREA

S. No

Name of the Location

Category of

Area/zone

Day Time in Leq dB (A)

CPCB Standard Day Time

Night Time in

Leq dB (A)

CPCB Standard

Night time

1. Project Site Industrial 65.3 75dB (A) 42.0 70dB (A)

2. Dondapadu Residential 53.4 55dB (A) 34.3 45dB (A)

3. Mukteshwarapuram Residential 53.5 55dB (A) 33.1 45dB (A)

4. Bugga Madharam Residential 52.8 55dB (A) 35.4 45dB (A)

5. Vajinepalli Residential 52.2 55dB (A) 37.5 45dB (A)

6. Ramapuram Residential 53.6 55dB (A) 37.6 45dB (A)

7. Budavada Residential 52.4 55dB (A) 37.5 45dB (A)

8. Jaggayyahpet Commercial 53.5 65dB (A) 36.1 55dB (A)

Daytime Noise Levels (Lday)

Industrial Zone: The day time noise level at the Project site was 65.3 dB(A), which

is well below the permissible limits of 75 dB(A).

Commercial Zone: The daytime noise levels in the commercial location was



Residential Zone: The daytime noise levels in all the residential locations were

observed to be in the range of 52.2 dB (A) to 53.6 dB(A). The noise levels at all the

locations were below the permissible limits of 55 dB(A).

Night time Noise Levels (Lnight)

Industrial Zone: The night time noise level in the Project site was observed be 42.0

dB(A), which is well below the permissible limits of 70 dB (A).

Commercial Zone: The night time noise levels in the commercial location was



Residential Zone: The nighttime noise levels in all the residential locations were

observed to be in the range of 33.1 dB(A) to 37.6 dB(A). The noise levels were

below the permissible limits of 45 dB(A) in nighttime at all the locations.



3.6.2 TRAFFIC STUDY

Anthropogenic emissions not only contribute to the green house effect but also

participate in the reaction that results in photochemical oxidants. The effect of

photochemical oxidants is well known for forming smog particularly in the urban

areas.Among the anthropogenic sources of pollutants forming the green house

gases, burning of fossil fuels constitute a major source. Highway mobile sources that

contribute significantly to poor quality have been regulated for the past two decades

in countries like India. The absence of regulation in developing countries has caused

a global concern regarding potential environmental damage on a larger scale.

The traffic survey was carried out on the Muktyala to Jaggayyapeta Road which is

2.5 km (ESE) to the Project site. Vehicular traffic counts were performed on either

side of the studied roads to provide background values of traffic density, and

correlate such data to the levels of air pollution along the road. Vehicular traffic on

these roads included heavy vehicle, light vehicle, three wheelers, and two wheelers.

The additional traffic due to the project would also occur in this time duration only. A

summary of the data is presented in Table 3.21.



TABLE 3.21: TRAFFIC STUDY AT MUKTYALA TO JAGGAYYAPETA ROAD (To & From)

S. No

Time Two

Wheelers 2 Wheeler

@ 0.75 PCU Three

Wheeler

3 Wheeler @ 1.2 PCU

Passenger cars

Passenger cars @ 1

PCU

Heavy vehicles

Heavy Vehicles

@3.7 PCU

Total vehicles

Total vehicles

PCU

1 06-07 am 107 80 32 40 118 118 272 1006 528 1244

2 07-08 am 147 110 35 51 125 125 309.6 1146 616 1431

3 08-09 am 179 134 39 78 160 160 294.4 1089 672 1461

4 09-10 am 183 137 42 96 170 170 280 1036 675 1439

5 10-11 am 156 117 45 125 190 190 266.4 986 657 1418

6 11-12 pm 145 109 50 139 178 178 256 947 628 1373

7 12-01 pm 126 95 54 130 167 167 248.8 921 596 1312

8 01-02 pm 120 90 53 106 150 150 241.6 894 564 1240

9 02-03 pm 124 93 48 102 145 145 227.2 841 544 1180

10 03-04 pm 116 87 45 95 131 131 196 725 487 1038

11 04-05 pm 106 79 40 90 128 128 180 666 453 963

12 05-06 pm 118 88 38 112 155 155 168 622 478 977

13 06-07 pm 129 97 35 125 145 145 160 592 469 959

14 07-08 pm 118 88 34 102 138 138 148.8 551 438 878

15 08-09pm 102 77 30 96 130 130 142.4 527 404 829

16 09-10pm 99 74 28 68 127 127 288 1066 542 1335

17 10-11pm 93 70 25 52 129 129 352 1302 599 1553

18 11-12pm 75 56 22 46 91 91 440 1628 628 1821

19 12-01am 68 51 19 35 59 59 256 947 402 1092

20 01-02am 54 41 15 28 45 45 240.8 891 355 1004

21 02-03am 45 34 14 19 42 42 234.4 867 335 962

22 03-04am 36 27 19 8 50 50 144 533 249 618

23 04-05am 46 34 25 12 73 73 125.6 465 269 584

24 05-06am 53 40 29 29 98 98 224 829 403 995

The highest peak observed during 11 am to 10 pm (worst Scenario) PCU/hr 1821

Total width of the Road in meters (Arterial Road) 24



Carrying capacity of the road (the road is 4 lane Divided 2 way road) As per IRC:106-1990 (PCU’s per hour) 3600

Existing V/C Ratio 0.51

LOS=Level of Service (Existing)

V/C LOS Performance

0.0-0.2 A Excellent

0.2-0.4 B Very Good

0.4-0.6 C Good

0.6-0.8 D Fair/Average

0.8-1.0 E Poor

1.0 & above F Very Poor

Note: *As per IRC Guidelines 1990

The traffic survey was carried out on the Muktyala to Jaggayyapeta Road which is 2.5 km (ESE) to the Project site. The details of

the vehicles movement recorded. From the study it is observed that there is no major impact on traffic due to the proposed project.



3.7 SOIL ENVIRONMENT

The present study on soil quality establishes the baseline characteristics in the study

area surrounding the project site. The study has been addressed with the following

objectives.

To determine the base line characteristics

To determine the soil characteristics of plant site and surrounding areas with

in 10 km radius.

To determine the impact of industrialization/urbanization on soil

characteristics

To determine the impacts on soils from agricultural productivity point of view.

The soil samples were collected during study period. Sampling Locations are

detailed in Table 3.22. and Figure 3.13. The analysis results are given in Table 3.23.

Details of Standard Soil Classification are given in table 3.24.

The homogenized soil samples collected at different locations were packed in a

polyethylene plastic bag and sealed. The sealed samples were sent to laboratory for

analysis. The important physical, chemical parameter concentrations were

determined from all samples.

TABLE 3.22: SOIL SAMPLING LOCATIONS

S. No. Code Name of Sampling Location Distance (km) w.r.t Project


1 S1 Project Site -- --

2 S2 Dondapadu 1.4 WSW

3 S3 Mukteshwarapuram 2.6 E

4 S4 Bugga Madharam 2.2 SE

5 S5 Vajinepalli 3.7 SSE

6 S6 Ramapuram 5.7 WNW

7 S7 Budavada 5.6 NNW

8 S8 Kautavari Agraharam 6.7 NE



FIGURE 3.13: SOIL SAMPLING LOCATIONS MAP



TABLE 3.23: SOIL SAMPLING ANALYSIS RESULTS

S.No Parameters Units S1 S2 S3 S4 S5 S6 S7 S8

1 PH -- 7.05 6.92 6.85 7.21 6.90 7.52 6.90 7.32

2 Electrical Conductivity µ mhos 275.0 75.4 95.3 80.9 78.5 89.6 95.4 101.5

3 Bulk Density g/cc 1.11 1.20 1.21 1.22 1.18 1.14 1.13 1.12

4 Moisture Content % 5.80 5.92 5.85 5.90 5.45 5.60 5.25 5.31

5 Nitrates as N mg/Kg 1.50 1.30 1.42 1.35 1.42 1.52 1.61 1.62

6 Phosphorous as P mg/Kg 14.3 9.8 8.6 4.60 4.52 4.39 4.22 4.51

7 Potassium as K mg/Kg 17.5 16.50 18.40 21.82 17.95 16.44 16.20 16.29

8 Sodium as Na mg/Kg 15.1 12.22 13.01 15.85 14.30 12.45 12.46 13.65

9 Calcium as Ca mg/ kg 320.5 350.0 339.0 245.0 350.0 419.0 390.0 375.0

10 Magnesium as Mg mg/ kg 212.5 235.5 315.5 260.2 256.0 320.1 351.0 330.0

11 Total Organic Carbon % 0.80 0.81 0.79 0.71 0.80 0.81 0.76 0.79

12 Type of Soil -- Silt Loam Silt

Loam Silt

Loam Sandy Loam

Sandy Loam

Sandy Loam

Sandy Loam

Sandy Loam

a) Sand (%) -- 36 36 39 49 45 44 40 41

b) Silt (%) -- 49 44 48 37 39 38 39 42

c) Clay (%) -- 15 16 13 14 16 18 21 17

13 Copper as Cu mg/ kg 11.3 8.20 7.75 7.37 8.15 7.85 7.64 8.25

14 Chromium as Cr mg/ kg 30.22 32.55 30.65 30.26 30.70 28.12 29.5 30.22

15 Cadmium as Cd mg/ kg <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5 <0.5

16 Zinc as Zn mg/ kg 35.4 32.24 34.21 28.45 29.25 31.45 26.42 26.47

17 Lead as Pb mg/ kg 10.5 11.21 10.56 9.25 10.42 10.29 10.52 10.90

18 Nickel as Ni mg/ kg 10.20 11.25 11.69 12.50 13.21 14.21 13.40 13.55

19 Sulphates as SO4 mg/ kg 80.4 42.35 31.24 32.54 35.65 34.22 38.05 39.52



Physicochemical characteristics of the soil samples obtained from 7 areas in the

buffer zone and one from the project site reveals that all basically Silt loams. It is due

to the fact that the upper soil layers are formed by the deposition of fine sand and silt

carried down by the storm waters from the surrounding areas. They are moderately

productive and they are not prone to water logging.

It has been observed that the pH of the soil quality ranged from 6.85 to 7.52.

Percentage of Total Organic Carbon is observed in between 0.76 to 0.81

indicating that On an avg. sufficient in nature.

Table 3.24 :STANDARD SOIL CLASSIFICATION

S.No Soil Test Classification

1 pH

<4.5 Extremely acidic

4.51- 5.50 Very strongly acidic

5.51-6.00 Moderately acidic

6.01-6.50 Slightly acidic

6.51-7.30 Neutral

7.31-7.80 Slightly alkaline

7.81-8.50 Moderately alkaline

8.51-9.00 Strongly alkaline

>9.00 Very strongly alkaline

2 Salinity Electrical Conductivity

(μS/cm) (1ppm = 640 μS/cm)

Upto 1.00 Average

1.01 - 2.00 harmful to germination

2.01 - 3.00 Harmful to crops (sensitive to salts)

3 Organic Carbon (%)

Upto 0.20: Very less

0.21- 0.40: Less

0.41- 0.50: Medium,

0.51- 0.80: On an avg. sufficient

0.81 - 1.00: Sufficient

>1.00 : More than sufficient

4 Nitrogen (kg/ha)

Upto 50 Very less

51-100 Less

101-150 Good

151-300 Better

>300 Sufficient

5 Phosphorus (kg/ha)

Upto 15 Very less

16-30 Less

31-50 Medium,

51-65 On an avg. sufficient

66-80 Sufficient

>80 More than sufficient



S.No Soil Test Classification

6 Potash (kg/ha)

0 -120 Very less

120-180 Less

181-240 Medium

241-300 Average

301-360 Better

>360 More than sufficient

Source: Hand book of Agriculture, ICAR, New Delhi

3.8 LAND USE PATTERN

Remote sensing satellite imageries were collected and interpreted for the 10-km

radius study area for analyzing the Land use pattern of the study area. Based on the

satellite data, Land use/ Land cover maps have been prepared.

Objectives

The objectives of land use studies are:

To determine the present land use pattern;

To analyze the impacts on land use due to the proposed project in the study

area; and

To give recommendations for optimizing the future land use pattern and

associated impacts.

3.8.1 DATA USED

The data is used for the preparation of different maps for the study natural

resources. The data is used by using the application of Remote Sensing and GIS

technologies.

TABLE 3.25: SHOWING THE DETAILS OF SOURCES & THE MAPS PREPARED

S No. Source Maps Prepared

1 Survey of India’s topographic maps and satellite imageries

Drainage map

2 Satellite imageries Land use / Land cover

TABLE 3.26: SHOWING THE TOPOGRAPHIC MAPS

Sl. No.

Topographic Map No.

Scale Year of Survey

Year of Publication

1. 56 P/13 1: 50,000 2010 2011

2. 56 P/14 1: 50,000 2010 2011

3. 65 D/1 1: 50,000 2010 2011

4. 65 D/2 1: 50,000 2010 2011 Source:Survey of India’s Topographic Maps



TABLE 3.27:SATELLITE DATA OF NATIONAL REMOTE SENSING CENTRE

S.No. Season Sensor path/row Satellite/Sensor Date of Pass

1. Khariff 101-61-B IRS RS-2 LISS IV

FX 11-September-

2018

3.8.2 LAND USE / LAND COVER MAP

Land use / land cover map is prepared by visual interpretation of high-resolution

satellite data with the help of Survey of India Topographic maps on 1:50,000 scale.

Two seasons’ data (Khariff year 2018) is used for the delineation of different units.

The units are confirmed by the ground truth/field visits.

Level-II classification of National (Natural) Resources Information System (NRIS)

has been followed for the delineation of units.

Land use/ Land cover map of the study area is integrated with village map and

analyzed with the help of GIS to get the village wise findings of the present land use

of the study area, which is given elaborately in the following tables:

Land use refers to man’s activities and various uses, which are carried on land. Land

cover refers to natural vegetation, water bodies, rock/soil, artificial cover and others

resulting due to land transformation. Although land use is generally inferred based

on the cover, yet both the terms land use and land cover are closely related and

interchangeable. Information on the rate and kind of change in the use of land

resources is essential to the proper planning, management and regulation of the use

of such resources.

Knowledge about the existing land use and trends of change is essential if the nation

is to tackle the problems associated with the haphazard and uncontrolled growth. A

systematic framework is needed for updating the land use and land cover maps that

will be timely, relatively inexpensive and appropriate for different needs at national

and state level. The rapidly developing technology of remote sensing offers an

efficient and timely approach to the mapping and collection of basic land use and

land cover data over large area. The satellite imageries are potentially more

amenable to digital processing because the remote sensor output can be obtained in

digital format. Land use data are needed in the analysis of environmental processes

and problems that must be understood if living conditions and standards are to be

improved or maintained at current levels.



3.8.2.1 Basic Concepts of Land Use

Clawson has given nine major ideas or concepts about land. These are:

Location or the relation of a specific parcel of land to the poles, the equator,

and the major oceans and landmasses. There is also relationship between

various tracts of land, as well as a political location.

Activity on the land, for what purpose this piece of land or tract is used.

Natural qualities of land, including its surface and subsurface characteristics

and its vegetative cover.

Improvements to and on the land. This is closely related to the activity.

Intensity of land use or amount of activity per unit area.

Land tenure, i.e. who owns the land, which uses it.

Land prices, land market activity and credit as applied to land.

Interrelations between activities on the land and other economic and social

activities.

Interrelations in the use between different tracts of land.

3.8.2.2 Methodology for land use / land cover mapping

The land use / land cover map is prepared by adopting the interpretation techniques

of the image in conjunction with collateral data such as Survey of India topographical

maps and census records. Image classification can be done by using visual

interpretation techniques and digital classification using any of the image processing

software. For the present study, ERDAS 9.1 version software is used for

preprocessing, rectification, enhancements and classifying the satellite data for

preparation of land use land cover map for assessing and monitoring the temporal

changes in land use land cover and land developmental activities.

The imagery is interpreted and ground checked for corrections. The final map is

prepared after field check. Flow chart showing the methodology adopted is given in

the different land use / land cover categories in the study area has been carried out

based on the NRSC land use / land cover classification system.

For analysis and interpretation, and preparation of LU / LC map, two types of data

are needed:

1. Basic data 2. Ground data



1. Basic data includes:

Fused data of LISS IV

Toposheets on 1 : 50,000

Local knowledge

Area map on any scale to transfer details

Reports and other literature of the study area

2. Ground data: Ground data is very much essential to verify and to increase the

accuracy of the interpreted classes and also to minimize the field work.

Data analysis: For analysis and interpretation of satellite data, the study can be

divided into three parts:

Preliminary work

Field work

Post field work

A. Preliminary work includes:

to see the limitation of satellite data

to lay down the criteria for land use classification to be adopted

to fix the size of mapping units, which depends upon the scale

interpretation of different land use/land cover classes

demarcation of doubtful areas

preparation of field land use/land cover map

B. Field work:

Type of ground data to be collected

Selection of sample area for final classification

Checking of doubtful areas

Change in land use/ land cover due to wrong identification, fresh

development, nomenclature.

General verification

C. Post field work:

Reinterpretation or analysis or correction of doubtful areas

Transfer of details on base map

Marginal information



Preparation of final land use/land cover map

A map showing Satelite Imagery Showing in Figure 3.15. A map depicting major land

use/ land cover classes comprising lands under agriculture, fallow land,

open/degraded vegetation; lands falling under water bodies, scrub and lands under

inhabitations is presented at Figure 3.16 and Flow chart for LU/LC mapping

methodology is presented at Flow chart 3.1.

The land use classification within a distance of ten kilometers from the project

location and the areas falling under the respective classifications are presented in

Table 3.28:



FLOW CHART 3.1 : LU/LC MAPPING METHODOLOGY

Basic data

Data source

IRS LISS IV FMX

Khariff

season

Rabi

season

Preparation of base maps

Interpretation and mapping of

land use /land cover categories

Ground verification of doubtful areas and modification of thematic details

Transfer of Khariff and Rabi season

land use/land cover details on to a single base map.

Area estimation of each

land use/land cover class.

Final land use/land cover

map with symbols and

colours

Development of

interpretation keys based

on image characteristics.

Validation and final

interpretation key

Secondary data



TABLE 3.28 : LAND USE / LAND COVER STATISTICS OF THE STUDY AREA

FIGURE 3.14 PIE DIAGRAM SHOWING LAND USE THE IN STUDY AREA

Built- Up Land7.5%

Waterbodies11.8%

Forest22.9%

Crop Land30.7%

Wastelands27.1%

S. No.

LANDUSE AREA (Sq. km) %

1. BUILT UP LAND A. Settlements/Air force area B. Industrial area

16.642 6.908

5.3 2.2

2. WATERBODIES A. Tank / River / Reservoir etc.

37.052

11.8

3. FOREST A. Scrub forest/Degraded forest

71.906

22.9

4.

CROP LAND A. Single crop B. Double crop C. Crop land forest D. Plantation

52.438 38.308 2.198 3.454

16.7 12.2 0.7 1.1

5.

WASTELANDS A. Land with scrub B. Land without scrub C. Sheet rock area D. Mining area E. Stony waste area

20.724 20.096 7.536 9.734

27.004

6.6 6.4 2.4 3.1 8.6

TOTAL 314 100



FIGURE 3.15: SATELLITE IMAGE OF THE STUDY AREA



FIGURE 3.9: LAND USE / LAND COVER MAP OF THE STUDY AREA



3.9 ECOLOGICAL ENVIRONMENT

Ecological studies are one of the important aspects of Environmental Impact

Assessment with a view to conserve environmental quality and biodiversity.

Ecological systems show complex inter-relationships between biotic and abiotic

components including dependence, competition and mutualism. Biotic components

comprise of both plant and animal communities, which interact not only within and

between themselves but also with the biotic components viz. physical and chemical

components of the environment.

Generally, biological communities are good indicators of climatic and edaphic

factors. Studies on biological aspects of ecosystems are important in Environmental

Impact Assessment for safety of natural flora and fauna. The biological environment

includes terrestrial and aquatic ecosystems.

Objectives of Ecological Studies

The present study was undertaken with the following objectives to assess both

terrestrial and aquatic habitats of the study area

To assess the nature and distribution of vegetation in and around the project site

To assess the flora & fauna in the study area;

To ascertain the migratory routes of fauna, presence of breeding grounds and

sensitive habitats in the study area, if any;

To assess the presence of protected areas in the study area;

To review the information from secondary sources and discuss the issues of

concern with the relevant authority and stakeholders;

Impact prediction based on primary and secondary data sources to formulate

mitigation measures.

3.9.1 Detailed Description Of Flora And Fauna

Assessment of flora and fauna study location: Flora and Fauna studies were

carried out by using least count quadrate method at following six locations. Trees

were sampled by taking quadrates of 25 m2 and shrubs 10 m2 and in case of

herbaceous vegetation of 1 m2 distributed randomly. There are no National Parks,

Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals within the

10Km buffer zone of the project site. Forests and water bodies present in the buffer

zone are listed in Table 3.29.



TABLE 3.29 - Ecological Sensitivity details of the project site and its buffer

zone of 10 KM Radius

Protected areas Direction WRT

Project site Proximity to the

Project site in Km.

National Parks, Wildlife Sanctuaries, Biosphere Reserves and Important Bird Areas

None Not applicable

Heritage site and Monuments: Buddhist Stupa near Jaggayyapet

Northeast

8.9

Vedadri Lakshmi Narasimha Swamy Temple

East 8

MonkeyRehabilitationCentre East 8.4

Reserve Forests

Budavada R.F North 2.8

Balusupadu R.F North 6

Jaggayyapeta Extension R.F East 5.8

KuntimadiR.F East Southeast 5.2

Venkatayapalem R.F East Southeast 5.8

Ginjupalle R..F Southeast 6.4

Venkatayapalem ExtensionR.F Southeast 6.0

Nemalipuri R.F East Southwest 7.6

Chintapalem R.F East Southwest 7.6

WaterBodies

Krishna River East Southeast 2.5

Paleru River Northwest to East 5.5

Pulichintala Dam & Reservoir South 5.9

Tank near Jaggayyapet Northeast 8.3

Tank near Ramapuram West Northwest 8.0

Old limestone mine pits at Sitaramapuram

Northeast 8.0

The project site is located in Sy. No. 108 & 109, Jayanthipuram Village, Jaggayyapet

Mandal, Krishna District, Andhra Pradesh. The Primary surveys were conducted in

and around project area and 10 km radius study area, Reserve forests, open areas

near villages, waste lands and agricultural lands along the water bodies to identify

the floristic composition of the area and listed the plants species identified in the

Project area and 10 km radius study area is given in Table 3.30.

FLORA: Based on the physical setting and the kind of distribution of flora and fauna,

the study area can be classified into cropland, forest land, terrestrial vegetation

structure and aquatic ecosystems etc.



TABLE 3.30: List of plants found in the project area

Scientific name Common or Local name Family

Abrus precatorius Guruvinda Fabaceae

Acacia ferruginea Pandra Khair Mimosaceae

Acacia catechu Khair / Nalla sandra Mimosaceae

Acacia farnesiana Muriki thumma Mimosaceae

Acacia leucophloea Tella tumma Mimosaceae

Acacia nilotica Nalla tumma Mimosaceae

Acacia planifrons Godugu Thumma Mimosaceae

Aristida depressa Grass Poaceae

Aristida hystrix Grass Poaceae

Aristida setacea Grass Poaceae

Asperagus racemosa Satavari Liliaceae

Azadirachta indica Vepa Meliaceae

Azima tetracantha Tella Uppili Salvadoraceae

Butea monosperma Modugu Fabaceae

Calotropis gigantea Tella Jilledu Asclepiadaceae

Calotropis procera Jilledu Asclepiadaceae

Canthium dicoccum Nalla balusu Rubiaceae

Canthium parviflorum Balusu Rubiaceae

Capparis zeylanica Kutajamu Capparidaceae

Carallua umbellata Kundeti Kommulu Apocynaceae

Carissa spinarum Kalivi / Vaaka Apocynaceae

Cassia auriculata Tangedu Caesalpiniaceae

Cassia fistula Rela Caesalpiniaceae

Catunaregam spinosa Manga / Chinna manga Rubiaceae

Cissus quadrangularis Nalleru Vitaceae

Cissus vitiginea Adavi Gummadi Vitaceae

Cordia dichotoma Bankiriki Cordiaceae

Cosmostigma racemosum Adavitamalapaaku Apocynaceae

Cryptostegia grandiflora Rubber vine Asclepiadaceae

Cymbopogon coloratus Grass Poaceae

Cymbopogon caesius Grass Poaceae

Cynodon dactylon Grass Poaceae

Cyperus rotundus Grass Cyperaceae

Decalepis hahiltonii Maredu kommulu Periplocaceae

Desmodium pulchellum Deyyapu mokka Fabaceae

Dichrostachys cinerea Sara Thumma Mimosaceae

Diospyros chloroxylon Ulinda Ebenaceae

Diospyros melanoxylon Tunki Fabaceae

Dodonaea viscosa Bandedu Sapindaceae

Euphorbia antiquorum Bontha Jemudu Euphorbiaceae

Heteropogon contortus Grass Poaceae

Holoptelia integrifolia Nemali naara Ulmaceae

Jatropha glandulifera Wild Castor Euphorbiaceae

Lantana camara Makkadambu Verbenaceae

Leptadenia reticulata Mukkupala Teega Asclepiadaceae

Maytenus emerginata Danti Celastraceae



Mimosa polyancistra Thumma Mimosaceae

Mimosa rubicaulis Pariki kampa Mimosaceae

Opuntia dillenii Brahma Jemudu Cactaceae

Prosopis juliflora English tumma Mimosaceae

Prosopis spicigera Jammi chettu Mimosaceae

Tarenna asiatica Kommi Rubiaceae

Wattakaka volubilis Tummudu teega Asclepiadaceae

Wrightia tinctoria Pala –kordusha Apocynaceae

Ziziphus numularia Nela regu Rhamnaceae

Ziziphus rugosus Regu Rhamnaceae

Ziziphus xylopyra Goti or gotti Rhamnaceae

3.9.2 Vegetation and Flora of the study area:

There are reserved forests and water bodies in the 10 Km buffer zone of the project

site but there no Wildlife Sanctuaries or National Parks or Biosphere reserves or

other eco-sensitive areas. The reserved forests of the study area belongto the

Southern dry deciduous forests and Tropical dry evergreen scrub forests of

Champion and Seth. They are highly degraded and a few patches of dense scrub

and thorny bushes could be noticed. But many forest elements are still present and

hence they have a fairly good amount of botanical diversity. The main species in

these forests are Acacia chundra, Acacia planifrons, Albizia amara. Balanites

aegyptiaca, Anisochilus carnosus, Canthium parviflorum, Erythroxylon monogynum,

Flacourtia indica, Premna tomentosa, Ziziphus spp., Dodonaea viscosa,

Euphorbiaantiquorum, Dichrostachiys cinera, Capparis brevispina, Maytenus

emarginata, Carissa sginarum, Grewia tenax, Cassia auriculata, Prosopis juliflora

and a few others. A list of plant species representing trees, shrubs and herbs list is

given in Table 3.31. A list of grasses, herbs, Climbers and herbaceous plants found

in the study area is given in Table 3.31.

There are no rare or endangered or threatened species all the species listed in Table

3.31 are widely distributed in most parts of Deccan region.

Cropland Ecosystem: The common crops land ecosystem in study area are Oryzha

sativa and Zea maze which are mainly dependent on rainwater during monsoon

season, canal irrigation and also through ground water source, tube wells and open

wells during non-monsoon season.



TABLE 3.31., List of Trees, Shrubs, Grasses, Herbs, Climbers and Herbaceous

Species Found the Study Area

Scientific name Common or Local name Family

Abrus precatorius Guruvinda Fabaceae

Acacia ferruginea Pandra Khair Mimosaceae

Acacia auriculiformis Australian Wattle Mimosaceae

Acacia caesia Korintha Mimosaceae

Acacia catechu Khair / Nalla sandra Mimosaceae

Acacia farnesiana Muriki thumma Mimosaceae

Acacia leucophloea Tella tumma Mimosaceae

Acacia nilotica Nalla tumma Mimosaceae

Acacia planifrons Godugu Thumma Mimosaceae

Acacia holosericea White Wattle Mimosaceae

Achrus sapota Sapota Sapotaceae

Aegle marmelos Maredu Rutaceae

Ailanthus excelsa Peddamaanu Simaroubaceae

Alangium salvifolium Ooduga Alangiaceae

Albizia amara Narlinga Mimosaceae

Albizia lebbek Dirisanam Mimosaceae

Alhagi camelorum Camel thorn Fabaceae

Allamanda cathartica Allamanda Apocynaceae

Anisochilus carnosus Karpuravalli Lamiaceae

Annona squamosa Seetaphalam Annonaceae

Anogeissus acuminata Pasi Combretaceae

Anogeissus latifolia Chirumaanu Combretaceae

Asperagus racemosa Satavari Liliaceae

Azadirachta indica Vepa Meliaceae

Azima tetracantha Tella Uppili Salvadoraceae

Balanites aegyptiaca, Gara chettu Zygophyllaceae

Bassia latifolia Ippa Sapotaceae

Bauhinia racemosa Aare chettu Caesalpiniaceae

Bauhinia variegata Mandari Caesalpiniaceae

Benkara malabarica Pedda manga Rubiaceae

Bombax malabariucm Silk cotton Bombacaceae

Borassus flabellifer Taati / Taadi Arecaace

Breynia retusa Chinna purugudu Euphorbiaceae

Breynia vitis-ideae Nalla purugudu Euphorbiaceae

Buchanania angustifolia Pedda -mori Anacardiaceae

Buchanania latifolia Char / Sarapappu Anacardiaceae

Butea monosperma Modugu Fabaceae

Callistemon citrinus Indian bottle brush tree Myrtaceae

Calotropis gigantea Tella Jilledu Asclepiadaceae

Calotropis procera Jilledu Asclepiadaceae

Calycoperis floribunda Bonta teega Combretaceae

Canthium dicoccum Nalla balusu Rubiaceae

Canthium parviflorum Balusu Rubiaceae

Capparis brevispina Indian Caper Capparaceae



Capparis zeylanica Kutajamu Capparidaceae

Caralluma umbellata Kundeti Kommulu Apocynaceae

Careya arborea Adavi Jaama / Kumbhi Lecythidaceae

Carissa spinarum Kalivi / Vaaka Apocynaceae

Cascabela thevetia Patcha ganneru Apocynaceae

Cassia auriculata Tangedu Caesalpiniaceae

Cassia fistula Rela Caesalpiniaceae

Carissa spinarum Kalivi Apocynaceae

Catunaregam spinosa Manga / Chinna manga Rubiaceae

Chloroxylon sweitenia Billudu Flindarsiaceae

Cissus quadrangularis Nalleru Vitaceae

Cissus vitiginea Adavi Gummadi Vitaceae

Cocos nucifera Coconut Arecaceace

Codiaeum varieigatum Croton Euphorbiaceae

Cordia dichotoma Bankiriki Cordiaceae

Cosmostigma racemosum Adavitamalapaaku Apocynaceae

Crataeva religiosa Urimidi Capparidaceae

Cryptostegia grandiflora Rubber vine Asclepiadaceae

Dalbergia sisso Sisso or Seesum Caesalpiniaceae

Decalepis hahiltonii Maredu kommulu Periplocaceae

Dendrocalamus strictus Bamboo / Veduru Poaceae

Desmodium pulchellum Deyyapu mokka Fabaceae

Dichrostachys cinerea Sara Thumma Mimosaceae

Diospyros chloroxylon Ulinda Ebenaceae

Diospyros melanoxylon Tunki Fabaceae

Dodonaea viscosa Bandedu Sapindaceae

Dolichondrone crispa Nirwodi Bignoniacae

Dolichondrone falcata Wodi Bignoniaceae

Erythina indica Indian coral tree Papilionaceae

Erythroxylon monogynum Dedaraaku Erythroxylaceae

Eucalyptus teretocronis Eucalyptus Myrtaceae

Eucalyptus hybrid Eucalyptus / Nilagiri Myrtaceae

Euphorbia antiquorum Brahma jemudu Euphorbiaceae

Ficus benghalensis Marri Moraceae

Ficus racemosa Medi Moraceae

Ficus religiosa Raavi Moraceae

Flacourtia indica Nakka neredu Salicaceae

Givotia rottleriformis Tella Poliki Euphorbiaceae

Glycomis mauritiana Tanaka Rutaceae

Grevellia robusta Silver oak Proteaceae

Grewia flavescens Jaana Tiliaceae

Grewia hirsuta Jaani Chettu Tiliaceae

Grewia obtusa Jaana Tiliaceae

Grewia orbiculata Pedda Jaani Tiliaceae

Grewia tillifolia Pedda Jaana Tiliaceae

Grewia villosa Bantha Tiliaceae

Grewia tenax Kaladi Tiliaceae

Hardwickia binata Yepi Caesalpiniaceae



Hemidemus indicus Sugandhapala Periplocaceae

Heterophragma roxburghii Bondudgu Bignoniaceae

Holoptelia integrifolia Nemali naara Ulmaceae

Hygrophila auriculata Gokulakanta Acanthaceae

Ipomoea carnea Rubber mokka Convolvulaceae

Jatropha glandulifera Wild Castor Euphorbiaceae

Kigelia africana Yenugu Paadam Bignoniaceae

Lagerstroemia parviflora Chennangi Lythraceae

Lantana indica Makkadambu Verbenaceae

Leptadenia reticulata Mukkupala Teega Asclepiadaceae

Leucaena leucocephala Subabul Mimosaceae

Limonia acidissima Velaga Rutaceae

Mangifera indica Mamidi Anacardiaceae

Maytenus emerginata Danti Celastraceae

Millingtonia hortensis Aakaasa malle Bignoniaceae

Mimosa polyancistra Thumma Mimosaceae

Mimosa rubicaulis Pariki kampa Mimosaceae

Mimosops elengi Pogada Sapotaceae

Morinda pubescens Togaru Rubiaceae

Moringa olivaefera Munaga Moringaceae

Muntingia calabura Wild cherry Elaeocarpaceae

Odina wodier Gumpena Anacardiaceae

Opuntia dillenii Naaga Jemudu Cactaceae

Oroxylum indicum Dundilam Bignoniaceae

Parkinsonia aculeata Jeeluga Widespread

Peltophorum pterocarpum Konda chinta Caesalpiniaceae

Pergularia daemia Dustapa teega Asclepiadaceae

Phoenix sylvestris Eetha Arecaceae

Phyllanthus emblica Usiri Euphorbiaceae

Phyllanthus reticulatus Pulasari / Puliseru Euphorbiaceae

Pithecellobium dulce Seema chinta Mimosaceae

Plumeria acutifolia Temple tree Apocynaceae

Plumeria alba Tella devaganneru Apocynaceae

Plumeria rubra Erra devaganneru Apocynaceae

Polyalthia longifolia Ashoka Annonaceae

Polyalthia pendula Asoka Annonaceae

Pongamia pinnata Ganuga Fabaceae

Premna tomentosa Wooly leaf Lamiaceae

Prosopis juliflora English tumma Mimosaceae

Prosopis spicigera Jammi chettu Mimosaceae

Quisqualis indica Rangoon creeper Combretaceae

Saccopetalum tomentosum Chilka dudi Annonaceae

Samanea saman Nidrabhangi Mimosaceae

Sapindus emarginatus Kunkundu Sapindaceae

Sarcostemma bevistigma Som Asclepiadaceae

Semecarpus ancardium Marking nut tree Anacardiaceae

Spathodea companulata Flame of the forest Bignoniaceae

Sterculia foetida Adavi badam Sterculiaceae



Syzigium cumini Neradu Myrtaceae

Tabermantana coronaria Nandivardhanam Apocynaceae

Tamarindus indica Chinta Caesalpiniaceae

Tarenna asiatica Kommi Rubiaceae

Tecoma stanns Patcha turai Bignoniaceae

Tectona grandis Teak / Teku Verbenaceae

Terminalia arjuna Tella maddi Combretaceae

Terminalia bellerica Taani / Taandra Combretaceae

Terminalia catappa Baadam Combretaceae

Terminalia tomentosa Nalla maddi Combretaceae

Thespecia populnea Ganga Raavi Malvaceae

Thevetia nerifolia Yellow oleander Apocynaceae

Tylophora indica Kukkapala teega Asclepiadaceae

Vitex negundo Vaavili / Nirgundi Verbenaceae

Wattakaka volubilis Tummudu teega Asclepiadaceae

Wrightia tinctoria Pala –kordusha Apocynaceae

Ziziphus numularia Nela regu Rhamnaceae

Ziziphus rugosus Regu Rhamnaceae

Ziziphus xylopyra Goti or gotti Rhamnaceae

Though most of the annual herbs and therophytes had completed their life cycle and

withered away, most of them were represented by a few individuals in areas along

the river banks and croplands. A list of herbaceous species found during the survey

are listed in Table 3.32.

TABLE 3.32., Herbaceous species found the Study Area

Scientific name Family

Abutilon crispum Malvaceae

Abutilon indicum Malvaceae

Acalypha indica Euphorbiaceae

Achyranthes aspera Amaranthaceae

Adhatoda vasica Acanthaceae

Aerva lanata Amaranthaceae

Aerva tomentosa Amaranthaceae

Ageratum conyzoides Asteraceae

Alloteropsis cimicina Poaceae

Amaranthus spinosus Amaranthaceae

Andropogon jwarancusa Poaceae

Argemone mexicana Papaveraceae

Aristida depressa Poaceae

Aristida hystrix Poaceae

Aristida setacea Poaceae

Aristolochia bracteata Aristolochiaceae

Boerhaavia diffusa Nyctaginaceae

Bothriochloa pertusa Poaceae

Brachiaria cruciformis Poaceae

Brachiaria distachya Poaceae



Brachiaria mutica Poaceae

Brachiaria reptens Poaceae

Bulbostylis barbata Cyperaceae

Cassytha filiformis Lauraceae

Cenchrus ciliaris Poaceae

Chloris barbata Poaceae

Chrysopogon fulvus Poaceae

Cissus quadrangularis Ampelidaceae

Citrullus vulgaris Cucurbitaceae

Cleome aspera Capparidaceae

Cleome gynandra Capparidaceae

Conyza stricta Asteraceae

Crinum asiaticum Amaryllidaceae

Crotalaria verrucosa Fabaceae

Croton bonplandianum Euphorbiaceae

Cymbopogon coloratus Poaceae

Cymbopogon caesius Poaceae

Cynodon dactylon Poaceae

Cyperus rotundus Cyperaceae

Datura metel Solanaceae

Desmodium gangeticum Fabaceae

Desmodium triflorum Fabaceae

Dichanthium annulatum Poaceae

Dichanthium caricosum Poaceae

Eremopogon faveolatus Poaceae

Evolvulus alsinoides Convolvulaceae

Evolvulus nummularis Convolvulaceae

Heteropogon contortus Poaceae

Hibiscus micranthus Malvaceae

Hyptis suaveolens Lamiaceae

Indigofera enneaphylla Fabaceae

Ipomoea carnea Convolvulaceae

Neptunia triquetra Mimosaceae

Oldenlandia umbellata Rubiaceae

Parthenium hysterophorus Asteraceae

Polycarpaea corymbosa Caryophyllaceae

Ruellia tuberosa Acanthaceae

Rungia repens Acanthaceae

Scilla indica Asparagaceae

Sida acuta Malvaceae

Sida cordifolia Malvaceae

Tragia involucrata Euphorbiaceae

Trainthema portulacastrum Ficoidaceae

Tridax procumbens Asteraceae

Urginea congesta Liliaceae

Urginea coromandeliana Liliaceae

Waltheria indica Sterculiaceae

Withania somnifera Solanaceae



3.9.3. Terrestrial fauna of the project area and the study area

As the animals, especially vertebrates and the winged invertebrates move from place

to place in search of food, shelter, mate or other biological needs, separate lists for

core and buffer areas are not desirable. The buffer zone is subjected to

anthropogenic disturbances and biotic pressures of grazing. As such there are no

chances of occurrence of any rare or endangered or endemic or threatened (RET)

species within the core or buffer area. There are no Sanctuaries, National Parks,

Tiger Reserve or Biosphere Reserve or Elephant Corridor or other protected areas

within 10 Km of radius from core area. It is evident from the available records,

reports and circumstantial evidence that the entire study area including the core and

buffer areas were free from any endangered animals except those in the Krishna

River and the Pulichintala Reservoir. Among the Mammals, only Squirrels,

Mongoose, Rats, Bandicoots and Rabbits were seen noticed during the survey.

Monkeys were also rare. Among the reptiles, Lizards, Garden lizards were

common. Rat snake was seen during the survey. Other reptiles were very rare. The

amphibians were also rare. A list of Mammals, Reptiles and Amphibians either found

or reported from the area is given in Table 3.33. There were no resident birds other

than Crows, Parrots, Doves, and Weaver birds, Swifts, Quails and Mynas. It is

apparent from the list that Mugger Crocodile (Crocodyluspalustris), Common Indian

Monitor (Varanus bengalensis), Indian Flap-shell Turtle (Lissemys punctata), Indian

Tent Turtle (Pangshura tentoria) andAsian Giant Softshell Turtle (Pelochelys

cantorii), reported from the Krishna River and Pulichintala Reservoir belong to

Schedule I of the Indian Wildlife (Protection) Act 1972.

A list of birds either spotted or reported or recorded from the area under

consideration is given in Table 34. The data is verified with Avibase and there are no

RET species or Schedule I species.

3.9.3.1 Methodology for Mammals study: The mammal survey was carried out by

walking through different forest habitats, recording and collecting evidence of

mammals. Besides fixed transect survey as far as possible, random search was also

adopted to record the occurrence of mammalian species in the study area. Indirect

evidences such as scats, pug/foot marks, calls of different mammalian species and

discussion with the villagers in the surrounding villages were used for the identification

and documentation of the mammalian species there are several minor carnivorous and



herbivorous wild animals in the study area. The commonly observed or reported

mammals during study period are presented in below Table No. 3.33.

3.9.3.2 Methodology for Herpeto-fauna: Herpeto-fauna were noticed mainly in fresh

water and marshy places Different amphibians, Butterflies: Butterflies spotted in the

study area were identified as per Butterflies of India.

3.9.3.3 Methodology for Birds in Study Area: Survey for birds was done in

different areas like wetlands, forest types and cultivation lands. Birds were observed

mostly during most active period of the day around 5.30 hrs to 8.30 hrs and 15.30

hrs to 18.30 hrs. Birds were identified by direct observation, identifying the physical

features with the help of field guides (The book of Indian Birds by Salim Ali) and

reference books. In case of complications in identification, photographs were taken

for identification in later stages. Birds were observed in different types of habitats

and those areas where sighting chances are more. However, time schedule was

altered according to situation and availability of time.

TABLE 3.33 List of vertebrates other than birds found in and around the

project site.

Common / Local name Scientific name WPA

Schedule

MAMMALS

Large bandicoot rat Bandicota indica IV

Short-nosed fruit bat Cynopterus sphinx IV

Three striped squirrels Funambulus palmarum IV

Indian bush rat Golunda ellioti IV

Indian grey mongoose Herpestes edwardsii IV

Indian crested porcupine Hystrix indica IV

Common Indian field mouse Mus booduga IV

Home mouse Mus musculus IV

Bandicoot rat Nosokia indica IV

Indian pygmy pipistrelle Pipistrellus mimus IV

Long-eared bat Plecotus auritus IV

Common Indian rat Rattus rattus IV

Greater yellow bat Scotophillus heathi IV

Savvy pygmy shrew Suncus etruscus IV

House shrew Suncus murinus IV Wild boar Sus scrofa III

REPTILES

Common Indian Krait Bungarus caeruleus II



Garden lizard Calotes versicolor IV

Chameleon Chameleon zeylanicus II

Tree Snake Chrysopelea taprobanica II

Mugger Crocodile Crocodyluspalustris I

Whip Snake Dryphis nasutus II

Saw scaled viper Echis carinatus II

Indian star tortoise Geochelone elegans II

Indian wall lizard Hemidactylus flaviviridis IV

Cobra Naja naja II

Rat snake Ptyas mucosa II

Blind Snake Typhlops diardii IV

Slender Blind Snake Typhlops porrectus II

Common Indian Monitor Varanus bengalensis I

Russell’s viper Vipera russseli II

AMPHIBIANS

Indian Narrow-headed Softshell Turtle

Chitra indica II

Bicolored frog Clinotarsus curtipes Endemic to South India

Common Indian Toad Duttaphrynus melanostictus IV

Green pond frog Euphlyctis hexadactylus IV

Indian Star Tortoise Geochelone elegans IV

Indian Bull Frog Hoplobatrachus tigerinus IV

Indian Flap-shell Turtle Lissemys punctata I

Indian Pond Terrapin Melanochelys trijuga IV

Indian Roofed Turtle Pangshura tecta IV

Indian Tent Turtle Pangshura tentoria I

Asian Giant Softshell Turtle Pelochelys cantorii I

Common Tree Frog Polypedates leucomystax IV

Common tree frog Polypedates maculatus IV

Indian Burrowing frog Sphaerotheca breviceps IV

http://vindhyabachao.org/wildlife_guidelines/schedule_species_reptiles.pdf *Schedule species (Reptiles) :Indian wildlife (Protection) Act, 1972

TABLE 3.34 List of Birds either spotted or reported from the areas in and

around the project site.

Scientific Name Common Name Family WPA

Schedule

Accipiter badius Shikra Accipitridae IV

Acridotheres tristis Common myna Sturnidae IV

Aegithinia tiphia Common Iora Irenidae IV

Alcedo atthis Smallblue kingfisher Alcedinidae IV

Amaurornis phoenicurus White-breasted waterhen

Recurvirostridae IV

Anas poecilorhyncha Spot-billed duck Anatidae IV

Ardea cinerea Grey Heron Ardeidae IV

Ardeola grayii Pond Heron Ardeidae IV

http://vindhyabachao.org/wildlife_guidelines/schedule_species_reptiles.pdf



Athene brama Spotted owlet Noctuidae IV

Bubulcus ibis Cattle Egret Ardeidae IV

Centropus sinasis Greater coucal Phasianidae IV

Ceryle rudis Lesser pied Kingfisher Alcedinidae IV

Columba livia Blue rock pigeon Columbidae IV

Coracias benghalensis Indian roller Coraciidae IV

Corvus splendens House crow Corvidae V

Dendrocitta vagabunda Indian tree pie Corvidae IV

Dendrocygna javanica Lesser whistling-duck Anatidae IV

Dicaeum erythrorhynchos Tickell’s flower pecker Dicaeidae IV

Dicrurus macrocercus Black drongo Dicruridae IV

Egretta garzetta Little egret Ardeidae IV

Elanus caeruleus Black-shouldered kite Accipitridae IV

Eudynamys scolopace Asian koel Cuculidae IV

Fulica atra Coot Rallidae IV

Gallinula chloropus Indian Moorhen Rallidae IV

Halcyon smyrnensis White-Breasted King fisher

Alcedinidae IV

Hierococcyx varius Brain fever bird Ardeidae IV

Himantopus himantopus Black-winged stilt Recurvirostridae IV

Hydrophasianus chrugus Pheasant tailed Jacana Jacanidae IV

Lanius excubitor Great grey shrike Daniidae IV

lxobrychus cinnamomeus Chestnut bittern Ardeidae IV

Megalaima haemacephala Copper smith Barbet Capitonidae IV

Merops orientalis Small Bee eater Meropidae IV

Milvus migrans Black kite Accipitridae IV

Motacilla alba White wagtail Motacillidae IV

Motacilla flava Yellow wagtail Motacillidae IV

Motacilla maderaspatensis Large pied wagtail Motacillidae IV

Nectarinia asiatica Purple sunbird Nectariniidae IV

Nectarinia zeylonica Purple-rumped sunbird Nectariniidae IV

Oriolus oriolus Eurasian golden oriole Oriolidae IV

Passer domesticus House sparrow Passeridae IV

Perirocotus cinnomomeus Small Minivet Phasianidae IV

Phalacrocorax carbo Large Cormorant Phalacrocoracidae IV

Phalacrocorax niger Little cormorant Phalacrocoracidae IV

Porphyrio porphyrio Purple moorhen Rallidae IV

Prinia inornata Plain prinia Cisticolidae IV

Prinia socialis Ashy prinia Cisticolidae IV

Psittacula cyanocephala Blossom headed Parakeet

Psittacidae IV

Psittacula krameri Rose-Ringed Parakeet Psittacidae IV

Pycnonotus cafer Red-vented bulbul Pycnonotidae IV



Saxicolodies fulicata Indian robin Turdinae IV

Streptopelia chinensis Spotted dove Columbidae IV

Streptopelia decaocto Eurasian Collared-Dove Columbidae IV

Streptopelia Senegalensis Little brown dove Columbidae IV

Streptopelia tranquebarica Red Collared-Dove Columbidae IV

Sturnus pagodarum Brahminy starling Sturnidae IV

Turdoides caudatus Common babbler Timalinae IV

Upupa epops Common hoopoe Upupidae IV

Vanellus indicus Red-wattled lapwing Charadriidae IV

3.9.4 AQUATIC FLORA AND FAUNA:

The core area is completely dry and there are no pools or ponds on any major storm

water drain. Hence, the core area is devoid of any aquatic species. Krishna River

and the Pulichintala Reservoir are the main aquatic bodies. A lost of aquatic and

semiaquatic plants found along the banks of the water bodies and in shallow waters

is given in Table 7. A list of fishes reported and recorded from the Krishna River,

Paleru River and Pulichintala reservoir are compiled basing on Fishbase and

Laxmappa & Ravinder Rao Bakshi (2016) after cross checking with fisheries

database of Krishna District. A list of fishes reported and recorded from the Krishna

River in Suryapet and Jaggayyapet areas is given in Table 3.35. A few RET species

have been reported from the River.

TABLE – 3.35 Aquatic and semi aquatic macrophytes found along the banks

and in the shallow waters of Krishna River, Palleru River and Pulichintala

reservoir.

Latin name Family

Alternanthera philoxeroides Solanaceae

Azolla pinnata Azollaceae

Brachiaria mutica Poaceae

Carex cruciata Cyperaceae

Centella asiatica Apiaceae

Chrysopogon aciculatus Poaceae

Cynodon dactylon Poaceae

Cyperus arenarius Cyperaceae

Cyperus exaltatus Cyperaceae

Echinochloa colona Poaceae

Eichhornia crassipes Pontederiaceae

Hygrophila auriculata Acanthaceae

Ipomoea aquatica Convolvulaceae

Ludwigia perennis Onagraceae

Marsilia quadrifoliata Marsiliaceae



Nelumbo nucifera Nelumbiaceae

Nymphaea nauchali Nympheaceae

Nymphaea stellata Nympheaceae

Nymphoides hydrophylla Nympheaceae

Nymphoides indica Nympheaceae

Ottelia alismoides Hydrocharitaceace

Oxalis corniculata Oxalidaceae

Paspalidium geminatum Poaceae

Pistia stratoides Araceae

Typha angustata Typhaceae

TABLE – 3.36 List of Fishes reported from Krishna River, Palleru River and

Pulichintala Reservoir located in the buffer zone of the project site.

Scientific name English Name Local name IUCN

Status

Acanthocobitis botia Striped loach Jerri chepa LC

Amblypharyngodon microlepis

Indian carplet Kodipe LC

Amblypharyngodon mola Indian carplet Kodipe LC

Anabas testudineus Climbing perch Goraka chepa DD

Anguilla bengalensis Long-finned eel Malugu NT

Anguilla bicolor Indian short finned eel Malugu LC

Aplochelus lineatus Striped top-minnow Minnow-chepa LC

Awaous grammepomus Scribbled goby Uskedonthi LC

Bangana ariza Ariza labeo Aruzu LC

Bangana diplostoma Sind labeo Kodipe LC

Barbodes carnaticus Carnatic carp Perka-chapa LC

Barbodessarana sarana Olive barb Gandeparaka LC

Barbodessarana subnasutus

Peninsular Olive barb Parka LC

Barilius bakeri Malabar baril Kodipe LC

Barilius barila Barred baril Kodipe LC

Barilius barna Baranabaril Kodipe LC

Barilius bendelisis Spotted baril Kodipe LC

Carassius carassius Crucian Carp Pakke LC

Catla catla Katla Botcha LC

Channa gachua Dwarf snakehead Guruja LC

Channa marulius Giant snakehead Poo meenu LC

Channa punctata Spotted snakehead Buradamatta LC

Channa striata Striped snakehead Korrameenu LC

Chela cachius Silver hatchet chela Getchu LC

Cirrhinus cirrhosa White carp Aruza LC

Cirrhinus fulungee Deccan white carp Mosu LC

Cirrhinus mrigala Mrigal Yerramosu LC

Cirrhinus reba Reba carp Chittrai LC

Clarias gariepinus African catfish African marpu LC

Crossocheilus latius Stone roller Parkachepa LC

Ctenopharyngodon idella Grass carp Gaddi chepa LC



Cyprinus carpio Common carp Bangaruteega LC

Daniorerio Chintakuparega

Zebra danio Zebra fish LC

Devario aequipinnatus Giant danio Nooltu LC

Devario devario Sind danio Nooltu LC

Esomus danricus Flying barb Astapakke LC

Esomus thermoicos Flying barb Astapakke LC

Etroplus suratensis Banded pearl spot Duvenna chepa

LC

Gambusia affinis Mosquito fish Gambusia LC

Garra lamta Stone sucker Taatigoraka LC

Garra mcclellandi Stone sucker Banda pakiri LC

Garra mullya Stone sucker Banda pakiri LC

Glossogobius giuris Bar-eyed goby Isikadondu LC

Haludaria melanampyx Melon barb Parka DD

Hemibagrus maydelli Krishna mystus Ponduga LC

Heteropneustes fossilis Stinging catfish Ingilayee LC

Hypophthalmicthys molitrix

Silver carp Vendi chepa LC

Hypophthalmicthys nobilis

Big head carp Pedda Tala chepa

LC

Hyporhamphus limbatus Congaturi halfbeak Konga mukku LC

Hyporhamphus xanthopterus

Red-tipped halfbeak Konga mukku LC

Hypostomus plecostomus Suckermouth catfish Common pleco LC

Hypselobarbus dobsoni Krishna Carp Parka DD

Hypselobarbus jerdoni Jerdon’s carp Pakki LC

Hypselobarbus kolus Kolus barb Nilusu VU

Indoreonectes evezardi Evezardi loach Jerri chepa LC

Labeo bata Bata Mosu LC

Labeo calbasu Kalbasu Kakiparaka LC

Labeo dussumieri Common labeo Parka LC

Labeo fimbriatus Fringe- lipped carp Chitra LC

Labeo gonius Kurialabeo Mosu LC

Labeo kawrus Deccan labeo Parka LC

Labeo kontius Pig-mouthcarp Pandigande LC

Labeo microphthalmus Murreelabeo Parka LC

Labeo porcellus Bombay labeo Moyya LC

Labeo potail Deccan labeo Baman- chepa LC

Labeo rohita Rohu Seelavathi LC

Laubuca laubuca Indian glass barb Getchu LC

Lepidocephalichthys berdmorei

Leopard Loach Vulicha LC

Lepidocephalicthys guntea

Guntea loach Ulsha LC

Macrognathus aral One stripe spiny eel Bommidai LC

Macrognathus guentheri Malabar spiny eel Bommidai LC

Macrognathus pacalus Barred spiny eel Kontemukku LC

Mastacembelus armatus Zig – zag spiny eel Kontemukku LC



Megarasbora elanga Bengala Barb Kattekodipe LC

Mystus gulio Long whiskered catfish Jella LC

Mystus tengra Tengra mystus Jella LC

Mystus vittatus Stripped dwarf catfish Errajella LC

Nemacheilus anguilla Black lined loach Jerri chepa LC

Neotropius atherinoides Indian potasi Akujella LC

Oreochromius mossambicus

Mozambique Tilapia Doobotcha LC

Oreochromius niloticus Nile tilapia Doobotcha LC

Osphronemus goramy Giant gourami Gourami LC

Osteobrama vigorsii Deccan cotio Khira LC

Osteochilichthys thomassi

Konti barb Pedda parka LC

Osteochilus nashii Nashis barb Pedda parka LC

Pangasius pangasius Pangash Banka jella LC

Parambassis ranga Indian glassy fish Sarawa LC

Puntius amphibius Scarlet banded barb Perka-chapa DD

Puntius chola Swamp barb Pakki LC

Puntius conchonius Stigma barb Perka-chapa LC

Puntius dorsalis Long-snouted barb Perka LC

Puntius filamentosus Black-spot barb Perka LC

Puntius vittatus Silver barb Parigi chepa LC

Rasbora caverii Canvery rasbora Kodipe chepa LC

Rohtee ogilbii Vatanirohtee Aku chepa LC

Salmophasia acinaces Silver razor-belly minnow

Chela LC

Salmophasia bacaila Large razor-belly minnow

Chandamama LC

Schisturadenisonii dayi Dayi loach Jerri chepa LC

Schisturadenisonii denisonii

Denison's loach Jerri chepa LC

Sperata seenghala Giant river cat fish Multi jella LC

Tenualosa ilisha Indian shad Polasa LC

Tinca tinca Tench Tench LC

Tor khudree Deccan mahaseer Mansoor EN

Xenentodon cancila Freshwater garfish Vodla mukku LC

3.9.5 RET and Schedule I Fauna

On the basis of literature survey, from Red data books of Indian plants, detailed list

Rare and Endangered flora reveals that there are no Endangered, Threatened, Rare

plant species observed or recorded during study period.

There are no endangered animals, however recorded or observed list of wild animals

and their conservation status as per Wildlife (Protection) Act, 1972 are presented

above tables. As per Ministry of Environment, forests and climate change, Forest

department of Government of Andhra Pradesh state notifications reveals that there are



no Biospheres, Tiger Reserves, Elephant Reserves, National Parks, Wildlife

Sanctuaries, Conservation Reserves and Community Reserves in 10 - km radius from

plant boundary.

3.10. Socio Economic Study

The socio- economic aspects of people in the 10 km radius of the Project site of

Dondapadu village was analyzed. The socio-economic data forms the basis for

developing a suitable enterprise social responsibility plan to address the needs of the

population.

3.10.1. Methodology Adopted for the Study

The methodology adopted for the study mainly includes review of published

secondary data and primary data collection through sample survey conducted

project study area. Census of India - 2011 for respect to population, density,

household size, sex ratio, literacy rate and occupational structure for 10 km radius

study area.

3.10.2. Distribution of Population in the study area

As per 2011 census the study area consists of 1,80,636 persons inhabited in the

study area of 10 km radial distance from the periphery of the project. The distribution

of population in the study area is given in Table 3.37.

Table 3.37: Population Distribution

S.

No Name of Village

Number of

households

Total population 0-6 years aged population

Total Male Female Total Male Female

1 Chinthalapalem 1707 6597 3276 3321 807 389 418

2 Rama Puram 576 2250 1153 1097 214 116 98

3 Guddimalkapuram 237 896 442 454 103 54 49

4 Kothagudem 328 1199 605 594 118 62 56

5 Revuru 3081 11719 5973 5746 1270 662 608

6 Donda Padu 2552 9093 4576 4517 1028 512 516

7 Vajinepalle 494 1621 822 799 172 100 72

8 Nemalipuri 385 1476 748 728 194 108 86

9 Madharam 219 823 415 408 66 33 33

10 Jaggayyapeta 32711 126275 62713 63562 13801 7061 6740

11 Budawada 1196 4805 2480 2325 640 343 297

12 Tripuravaram 32 128 73 55 8 7 1

13 Jayanthipuram 619 2348 1191 1157 361 198 163

14 Mukteswarapuram 713 2742 1385 1357 253 134 119



15 Ravirala 316 1275 626 649 173 89 84

16 Vedadri 590 2155 1099 1056 231 105 126

17 Annavaram 1066 3917 2008 1909 440 229 211

18 Sreenivasapuram 356 1317 681 636 124 63 61

Total 47178 180636 90266 90370 20003 10265 9738 (Source: Hand Book of Statistics, Suryapet & Krishna District, 2011 and Census data 2011)

The male and female population constitutes about 49.97 % and 50.03 % in the study

area respectively. The graphical representation of total population distribution in the

study area was shown in Figure 3.17.

Figure 3.17: Diagram Showing Total Population Distribution in the Study Area

3.10.3. Literacy & Illiteracy Rate:

Literacy level is quantifiable indicator to assess the development status of any area.

The literate male and female in the study area are 60324 and 48184 which implies

that the percentage of literacy rate is 66.83 % with male and 53.32 % with female

respectively.

0

10000

20000

30000

40000

50000

60000

70000

80000

90000

100000

110000

120000

130000

140000

150000

160000

170000

180000

190000

Total population

Male Population

Female Population

Village Names

No

. o

f P

op

ula

tio

n



The male and female illiterates population in the study area are 29942 and 42186

respectively which implies that the percentage of illiteracy rate is 33.17 % with male

and 46.68 % with female respectively. The distribution of literate and literacy rate in

the study area is given in Table 3.38. The graphical presentation of literates and

illiterates in study area is given in Figure 3.12.

Table 3.38: Distribution of Literacy Rate and Illiteracy Rate in the Study Area

S. No Particulars Population

1. Male Population 90266

2. Female Population 90370

3. Total Population 180636

4. Male population Literates 60324

5. Male population Literates % 66.83 %

6. Male population illiterates 29942

7. Male population Illiterates % 33.17 %

8. Female population Literates 48184

9. Female population Literates % 53.32 %

10. Female population Illiterates 42186

11. Female population Illiterates % 46.68 % (Source: Hand Book of Statistics, Suryapet & Krishna District, 2011 and Census data 2011)

Figure 3.18: The Diagram Showing Literates and Illiterates in Study Area

3.10.4. Occupational Structure

The occupational structure of residents of work participation rate in the study area is

studied with reference to main workers, marginal workers and non workers. The

main workers include 10 categories of workers defined by the Census Department

60324

48184

29942

42186

Male Female

Literates Illiterates



consisting of cultivators, agricultural laborers, those engaged in live-stock, forestry,

fishing, mining and quarrying; manufacturing, processing and repairs in household

industry; and other than household industry, construction, trade and commerce,

transport and communication and other services.

The marginal workers are those workers engaged in some work for a period of less

than six months during the reference year prior to the census survey. The non-

workers include those engaged in unpaid household duties, students, retired

persons, dependents, beggars, vagrants etc.; institutional inmates or all other non-

workers who do not fall under the above categories.

Occupational pattern of the concerned study area is recorded to assess skills of

people and it also helps in identifying dominating economic activity in the area. In the

study area the main and marginal workers are 76041 and 12056 respectively of the

total population while the remaining 92539 constitutes non-workers.

Table 3.39: Occupational Structure in Study Area

S. No Parameter Total Male Female

1 Main Workers 76041 47926 28115

2 Marginal Workers 12056 4735 7321

3 Non-Workers 92539 37605 54934

Total Population 180636 90266 90370 (Source: Hand Book of Statistics, Suryapet & Krishna District, 2011 and Census data 2011)

Figure 3.19: The Diagram Showing Occupational Structure in Study Area

0

10000

20000

30000

40000

50000

60000

70000

80000

90000

100000

Total Male Female

Main Workers

Marginal Workers

Non-Workers

No

. o

f P

op

ula

tio

n



3.10.5 Civic Amenities Available In The Study Area

The project site is located near Chinthalapalem – where all the basic social

amenities like, Emergency Medicare, Drinking-Water, Communications,

Educational facilities, Roads and Power supply are readily available.

A) Power and Energy:

All Villages, in the Project Study Area, are electrified – both for common facilities

like, Street Lights, Public Water Pumping, etc. and also almost all houses are

electrified for home lighting, while LPG, Kerosene Oil and in some cases Waste

Agri-Waste, Fallen Firewood, Cow Dung Cakes, etc. are used for cooking

purpose.

B) Health and Medical Facilities:

Most Villages have PHCs or Visiting ANMs / Health Counseling-cum-Primary

Health Care Mobile Units. For Maternity and Specialist Care & basic Diagnostics,

adequate facilities are available near to project site, which is 10 km from the

proposed project site. And for Critical and Advanced Medicare & Diagnostics,

local communities visit Vijayawada City, which is about 66 km from the project

site.

Ambulance is available for emergencies to evacuate patients of serious health

condition/s to the Multi-Specialty.

C) Tele-Communications:

Telecommunication facility in the Project Study Area is adequate; BSNL

Electronic Telephone Exchange is available and BSNL / Airtel / Vodafone, Idea

Cellular & Reliance Telecom Services available everywhere.

D) Local Administration & Law:

While all the Villages and Towns do have ‘Village Panchayat’, duly elected by the

local electorates to assure Sanitation, Local Law & Order and to coordinate with

various Government Departments & Other Agencies, concerned for local

Sanitation, General Hygiene, Immunisation, Nutrition Programmes, Enhancement

of Literacy Levels and Crime / Law & Order as well as all Central and State

Governmental Developmental Projects.



E) Other Administrative Issues:

They are further supported by the Mandal Revenue Office (M.R.O.) stationed at

Mallareddygudem (9.3 km).

F) Transportation & Other Important Facilities:

The nearest Police Station, the Fire Station and Bus Station are located at

Jaggayyapet (8.0 Km) to the project site and there are also Bus-Station, Bus-

Stops at Jaggayyapet to all major Towns & Cities.

3.10.6 Corporate Social Responsibility of the Project Proponent

Due to proposed project there is no major negative impact on socio

economic environment.

The proposed project requires a workforce of 100 persons. Thus industrial

activity will boost up the commercial and economical status of the locality

to some extent. And, the overall impacts on socio-economic environment

due to the proposed project are positive in nature and accrue to the

community on the long-terms basis.

ANTICIPATED

ENVIRONMENTAL IMPACTS

&

MITIGATION MEASURES

CHAPTER -IV


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter – IV Page 196

CHAPTER - IV

ANTICIPATED ENIVORNMENTAL IMPACTS

& MITIGATION MEASURES

4.1 INTRODUCTION

Environment and development should be considered as mutually Complementary,

interdependent and an instrument of reinforcing the quality of life. Environmental

Impact Assessment (EIA) is the important aspect of overall environmental

management strategy and an important tool for sustainable development. It identifies

major impacts of Industrial and associated activities on environment and provides

guideline to prepare the necessary control measure termed as Environmental

Management Plan (EMP).

The identified impacts for various components of environment viz., Air, Noise, Water,

Land, Socio-Economy, etc. are presented herewith. EIA is an activity or an attempt

to identify, predict, evaluate and communicate the likely environmental impacts of the

activity/project on the environment.

Based on results [Baseline Data] of prediction and evaluation, pollution abatement

and control measures in order to mitigate the adverse impacts on the environment

are delineated in an Environmental Management Plan

The proposed project is likely to create impact on the environment in two distinct

phases:

During the construction phase, which may be temporary and short term; and

During the operation phase that would have long-term effects.

4.2. INVESTIGATED ENVIRONMENTAL IMPACTS DUE TO PROPSED PROJECT

The environmental impact assessment is accomplished by identification and

prediction of impacts and their assessment. Potential impacts of proposed project on

various environmental attributes given below are predicted;

Air environment

Water resources and quality

Noise levels

Land use

Soil quality

Solid waste



Terrestrial and aquatic ecology

Demography and socio-economics.

Hydrology & Geology

4.3. CONSTRUCTION PHASE

During the construction phase, the activities which are likely to contribute to impact

on various environmental components which are temporary in nature are site

clearing, leveling, construction of various structures of Drug manufacturing activities,

lying of internal roads, erection of equipment etc.

The construction activities will be confined within the project area of 9 acres.

The environmental impacts and management plan during construction phase are

detailed below.

4.3.1 IMPACT ON LAND USE

Present land is Barren. Now the site is converted in to industrial use and the

proposed project will be in an area of 9 Acres (36414 SQM) Change will occur on

the land use pattern of the surrounding villages

Any construction of infrastructure will lead to permanent change in land use pattern

at the site as a direct impact. No major changes in land use pattern will occur due to

the project activities.

4.3.2 IMPACT ON SOIL ENVIRONMENT

The activities of proposed project will be confined within the site premises. During

construction works, top soil generated from various activities like excavation etc. will

be stored and preserved to use it during restoration period as far as possible.

The construction activities will result in loss of topsoil and earthen material to some

extent in the plant premises. However, it is proposed to use the soil and earthen

material in greenbelt development.

No solid or hazardous waste will be generated during construction thus no impact on

soil environment is likely.

4.3.3 IMPACT ON TOPOGRAPHY

The proposed site is plain terrain and during the construction phase there would be

proper leveling of the proposed site. There is no additional stress expected due to



this project activity on topography and soil strategy of the project site and its

surroundings

Since it is a new project, changes occur in topography due to excavation of soil in

the proposed project area and construction of buildings and facilities. During

construction, excavated soil will be restored to its original shape. Thus the impact

during the construction is reversible, for short term and insignificant.

4.3.4 IMPACT ON AIR ENVIRONMENT

The sources of air emissions during construction phase will be due to development

of site, emissions from vehicles used for transportation of men and materials and

emission from construction equipment’s. These activities are likely to result in

emission of SO2, NO2, CO2 and Particulate matter. However, the quantity of these

will be very negligible and that too only for a very short period. Hence no adverse

impact on air quality is likely to occur.

4.3.5 IMPACT ON WATER ENVIRONMENT

No surface water body is located in the vicinity of the project site; hence project

related impact on water environment would mainly be limited to the groundwater

resources. The potential impacts during construction phases are assessed based on

the various activities.

● Improper disposal of construction debris may lead to off-site contamination of

water resources.

● Unaccounted disposal of domestic wastewater from temporary labour camps.

● Spillage of oil and grease from the vehicle maintenance activity and wastewater

stream generated from activities, such as vehicles washing and maintenance.

Site Workshop:

The repair and maintenance of equipments/ vehicles at site would generate waste

containing oil and grease. The wastewater stream would also be generated from

vehicle washing. The impact can be mitigated to a great extent by installing oil and

grease traps during construction phase.

Construction of Roads and Parking Areas:

The impact from the road construction depends on both the construction practices

and the type of material used. Construction waste of electrical installation, painting



and flooring may create significant impact. This type of waste would be stock piled

and disposed off to authorized vendor.

Development of the proposed site could lead to stockpiling and excavation activity on

site, thereby causing erosion of base soil. The run-off from the site may contain high

quantity of suspended solids (SS). The impact of runoff may not be very significant

except during rainy season. Further, construction of garland drains will reduce the

runoff from the stockpiles

Domestic Wastewater generated during construction, which will be collected in

sewage collection tank [septic tank]

The contamination of groundwater might occur due to the irrational disposal of liquid

wastes. The overall impact on water environment during construction phase due to

proposed project is likely to be short term and insignificant. There seems no impact

on the water environment of the study area.

4.3.6 IMPACT ON NOISE LEVELS

Noise will be generated due to construction traffic for loading and unloading,

fabrication and handling of equipment and materials are likely to cause an increase

in the ambient noise levels. The areas affected are those close to the site. However,

the noise will be temporary and will be restricted mostly to daytime.

4.3.7 IMPACT ON ECOLOGY

The proposed project will not involve removal of any vegetation from the soil and

loosening of the topsoil generally causes soil erosion as it is. However, such impacts

will be confined to the project site and will be minimized through paving and water

sprinkling. However, 37.51 % of greenbelt will be developed in the proposed project

site. The existing trees will be preserved to the extent possible. Thus, there will no

major adverse impacts are envisaged on ecological environment due to project

activities.

4.3.8 IMPACT ON SOCIO-ECONOMIC ENVIRONMENT

Due to proposed project there is no major negative impact on socio economic

environment. The proposed project will requires a workforce of 100 persons during

plant operations. Thus industrial activity will boost up the commercial and

economical status of the locality to some extent. And, the overall impacts on socio-



economic environment due to the proposed project are positive in nature and accrue

to the community on the long-terms basis.

TABLE – 4.1: Summary – Identification of Impacts During Construction Phase

S.No Components Aspect Potential Impacts

1 Topography & Geology

Site development No significant adverse Impacts

2 Soil

Construction activity leading to topsoil removal and erosion.

Minor negative impact

3 Landuse & Aesthetics

Land development Positive impact

4 Water Quality

Surface runoff from project site

Oil/ fuel and waste spills

Improper debris disposal

Discharge of sewage from labour camp.

Short term, but no significant negative impact

5 Ambient Air Quality

Dust emissions from site preparation, excavation, material handling and other construction activities at site.

Short term minor negative impact inside the site premises. No negative impact outside the site.

6 Noise

Noise generated from construction activities, operation of construction equipment and traffic.

Short term minor negative impact near noise generation sources inside premises. No significant impact on ambient noise levels at sensitive receptors.

7 Ecology Flora and Fauna

Habitat disturbance during construction activity.

Short term minor negative impact

8 Socio – economy

Increased job opportunity. Economy related to semiskilled expected to boom.

Short term positive impact by employment generation

9 Traffic Pattern

Haul Truck movement and possibility of traffic congestion outside site on Sector Road

Minor negative impact

10 Solid Waste Waste will be generated from construction activities

Proper disposal plan will be implemented. No adverse impact



4.4. MITIGATIVE MEASURES OF IMPACTS DURING CONSTRUCTION PHASE

Mitigative measures of identified impacts during construction phase are listed in

tabular form.

TABLE – 4.2: Mitigation Measures During Construction Phase

S. No

Components Impacts Mitigative Measures

1 Topography & Geology

No significant adverse Impacts

Construction will be carried out within the site premises; therefore no change will occur in land use pattern as well as there will not be any significant Topographical change. However, temporary change in top layer of soil will be occurred but the construction activity will help in fixation of soil thereby reducing the soil erosion

2

Land/Soil

Short term minor negative impact due to change in top layer of soil

The earthen material generated during excavations and site grading periods, will be properly dumped and slope stabilization shall be taken. The topsoil generated during construction shall be preserved and reused for plantations

Greenbelt development will have significant impact in reduction of the soil erosion

3 Ambient Air Quality

Sort term negative impacts because of dust emission due to site cleaning, road laying, earthwork, transportation & construction

The emissions will be temporary and confined within proposed project site boundary. It is not expected to contribute significantly to the ambient air quality However, the unit will take following measures for control of dust emissions:

Use of plastic cover sheet while transporting construction material at site

Storage of sand and other such dispersible material by covering with tarpaulin sheet

Storage of sand and other such dispersible material by covering with tarpaulin sheet

Keeping minimum inventory/stock of



S. No


sand and other such dispersible material at site

The heights, from which materials will be dropped, will be the minimum practical height to limit fugitive dust generation.

Use of water sprinkling system at site for dust suppression

During high wind condition, construction activities will be restricted, so that minimum flow of dust particle takes place.

Proposed Greenbelt development will be started from the construction phase

4 Water Quality

Short term, but no significant negative impact

Water requirement for construction phase will be very minor and for short period and that will be fulfilled by ground water source Thus, there will not be any significant impact on water environment

The wastewater generation will be from the domestic activities. Domestic effluent will be disposed of through septic tank into soak pit.

Measures will be implemented to prevent seepage of liquid materials into ground where it could contaminate groundwater and soil.

Fence will be constructed around the site to trap sediments whilst allowing the water to flow through.

All mud & dirt deposited on the roads from the construction activities will be cleaned.

5 Noise

Short term negative impact due to increase in noise level by site cleaning, road laying, earthwork, transportation & construction activities

The noise generated from construction machinery will be kept low by keeping the moving parts serviced and properly lubricated.

The construction activity will be carried out during day time only.

Vehicular movement carrying materials will be avoided during night time.

The vehicles will be regularly maintained and optimum use of the same will be made.



S. No


Adequate PPE’s (ear plugs, ear muffs helmet, mask etc) will be provided to the workers

Greenbelt development will have significant impact in reduction of the noise

6 Ecology Flora and Fauna

Short term minor negative impact but, long term positive impact due to green belt development

The felling of trees will be kept at minimum.

Adequate Greenbelt will be developed.

7 Socio - economy

Short term positive impact by employment generation

Temporary employment will be generated due to construction activities and related services like transportation of construction materials, mechanical erections etc. [25 Workers]

8 Traffic Pattern Minor negative impact

9 Solid Waste No adverse impact

Waste will be generated from construction activities Proper disposal plan will be implemented.

4.5. PREDICTION OF IMPACTS DURING OPERATIONAL PHASE

This phase of the project is important because it generates long-term impacts as the

production starts.

The following activities related to the operational phase will have varying impacts on

the environment and are considered for impact assessment:

Air environment

Water resources and quality

Noise levels

Land use

Soil quality

Solid waste

Terrestrial and aquatic ecology

Demography and socio-economics.

Hydrology & Geology



4.6 AIR ENVIRONMENT

The impacts on air quality from project depend on various factors like design

capacity, configuration, process technology, raw material, fuel to be used, air

pollution control measures, operation and maintenance. Apart from the above, other

activities associated with transportation of fuel, raw materials and finished products,

storage facilities and material handling within the plant premises may also contribute

to air pollution.

4.6.1 Source of Air Pollution

The operational phase activities are expected to have long - term impacts on the air

quality. The main sources from project are detailed below.

A. Flue gas Emissions

Boilers and DG set are the two main sources of emissions from the plant. Industry

proposed to install 2 TPH & 3 TPH coal fired boilers. A 500 KVA DG Set will be kept

as standby power during power failures.

PM, SO2 and NOx are the main air pollutants generated from the boilers and DG set.

The emissions from the boiler stacks and DG Set Stack are given in Table 4.3 & 4.4.

TABLE 4.3: Emission Details from Proposed Boiler Stack



Boiler


5000 kcal/kg


5000 kcal/kg


Ash Content % 35 35












TABLE 4.4: Emission Details from DG Set Stack




Stack dia. In m

Flue Gas Temp. in

OC

Stack Height in (m)


500 KVA 60 85 110 0.2 300 10 14

B. Process Emissions

The Predicted Process emissions are

CO2, [Carbon dioxide] – Pollutant

SO2, [Sulphur dioxide] - Pollutant

O2, [Oxygen] – Non Pollutant

HCl [Hydrochloric acid] - Pollutant

NH3 [Ammonia] – Pollutant

CH3Cl [Chloromethane] – Pollutant

HF [Hydrogen fluoride] – Pollutant

H2 [Hydrogen] - Non Pollutant

HBr [Methane] - Pollutant

Which will liberate from manufacturing process of proposed products. The process

emissions are based on reactants quantity and chemical reactions between them in

relation with desired product output.

C. Fugitive emission

The main sources of fugitive emissions from project are

Storage & Handling of raw materials

Storage & Handling of Solvents.

During reaction period

During Product filtrations & Finished operations

The raw materials will be stored in PP bags, Fibre drums and HDPE drums in

elevated flat from under the roof. Bulk quantities will be stored in storage tanks with

vent condensers to avoid the fugitive emissions. Solvents are handled in closed

conditions thereby reducing the losses in the form of evaporation.



4.6.2 Prediction of Impacts on Air Environment

The objective of dispersion modeling is to predict the ground level concentration

during the operation of plant and its impact on ambient air quality of the area.

Air quality assessment is done by integrating the measurement techniques and

modeling tools. The air modeling tools are routinely used in the environmental impact

assessments, risk analysis, emergency planning, and source apportionment studies.

Recent strategies for air pollution control in industries have largely neglected the

emission reduction measures which are the prime polluting sources. To accomplish

this, various air dispersion models have been developed and used worldwide so far

for different applications under different scenarios. The Gaussian plume model is a

standard approach for studying the transport of pollutants due to turbulent diffusion

and advection by the wind. Applications of such models have been made mandatory.

In this study, the AERMOD (the American Meteorological Society/Environmental

Protection Agency Regulatory Model Improvement Committee’s Dispersion Model,

Gaussian dispersion model is selected to predict the ground level concentrations

(GLC’s) of Particulate Matter (PM) µg/m3, sulphur dioxide (SO2) µg/m3 , and oxides

of nitrogen (NOx)- µg/m3 from point source emissions will be investigated in the

study area.

Methodology

Prediction of GLC values are made by using AERMOD software approved by U.S.

Environmental Protection Agency (USEPA) and has adopted it as its regulatory

model since 2005. In point source emissions, the stacks are subjected to plume rise

which again is dependent on force of buoyancy and momentum. The higher is the

plume rise or stack, the lesser will be ground level concentrations (GLC’s).The

emissions when released into the atmosphere are subjected to transportation,

dispersion, transformation, and fall out and wash out and finally reach the ground

level at a particular distance and concentrations. The relationship between the

source of emissions and its magnitude with the ground level concentrations (GLC’s)

at receptor points is governed by air dispersion models which take into the account

by the source strength, plume rise, atmospheric stability, mixing height, wind

velocity, terrain and other meteorological conditions. The comparison between the

predicted and field sampled downwind concentrations for PM, SO2 & NOX (µg/m3)



will be carried out in this study to predict the average downwind ground level

concentrations (GLC’s)

Data Used for Computation

Stack emissions data have been used for prediction of short-term incremental GLC

values of PM, SO2 & NOx using the meteorological data collected at site during the

Oct – 2018 to Dec – 2018. Details of the data used for computations are given

below:

Source Characteristics/Release Characteristics

The details of estimated stack emissions load are given in Table 4.2.

Meteorological Data

The meteorological data recorded continuously during the month of Oct – 2018 to

Dec - 2018, on hourly basis. AERMOD model requires hourly surface data values for

wind speed, wind direction, temperature, relative humidity and cloud cover. Both

data files for the surface and profile files were then used to generate the

meteorological file required by the AERMOD dispersion model using the AERMET

meteorological pre-processor. This AERMET has three stages to process the data.

The first stage extracts meteorological data and assesses data quality through a

series of quality assessment checks. The second stage merges all data available for

24-hour periods and writes these data together in a single intermediate file. The third

and final stage reads the merged meteorological data and estimates the necessary

boundary layer parameters for dispersion calculations by AERMOD.

Dispersion Modeling Results

The 24 hourly average ground level concentration (GLC) values from plant have

been computed for PM, SO2 & NOx considering topographical features around the

plant and applicable stability classes. The maximum 24 hourly average GLC values

for PM, SO2 & NOx from plant are given in Table 4.5 to Table 4.6. Corresponding

isopleths plotted are shown in Figure 4.1 to Figure 4.3 for PM, SO2 & NOx.



TABLE 4.5: Predicted 24-Hourly Short Term Incremental Concentrations

Season Maximum Incremental GLCs

(μg/m3) Distance

(km) Direction

PM SO2 NOx

Oct – 2018 to Dec – 2018

0.975 2.34 2.59 0.5 NW

TABLE 4.6: Resultant Concentrations Due to Incremental GLC's

Pollutant

Maximum Baseline

Concentration (μg/m3)

Incremental Concentrations due to Proposed Project

(μg/m3)

Resultant Concentration

(μg/m3)

NAAQ Standards (μg/m3)

PM 69.3 0.975 70.275 100

SO2 15.4 2.34 17.74 80

NOx 22.8 2.59 25.39 80

With this marginal contribution due to the proposal of the project, the levels of PM,

SO2 & NOx will remain below the 24 –hourly ambient air quality standards for SO2 &

NOx (80 μg/m3) and PM10 (100μg/m3) prescribed by CPCB. The operation of plant is

not likely to cause any significant impact on the ambient air quality of the study area.



FIGURE - 4.1: SHORT TERM 24 HOURLY INCREMENTAL GLCs OF PM



FIGURE - 4.2: SHORT TERM 24 HOURLY INCREMENTAL GLCs OF SO2



FIGURE - 4.3: SHORT TERM 24 HOURLY INCREMENTAL GLCs OF NOX



MITIGATION MEASURES

The industry will take measures for reduction of fugitive emissions emanating out of

process reactions by adopting the following;

Good ventilation will be provided to reduce the workroom concentrations.

Fugitive emissions will be reduced by providing vent condensers to the all the

reactors and Storage tanks.

Adequate stacks of height 30 mts will be provided to the 2 TPH & 3 TPH

boilers respectively.

Stack monitoring facilities for the periodic monitoring of the stack to verify the

compliance of the stipulated norms. Apart from this Cyclone Separator, Bag

filters will be provided to the boiler.

Table No.4.7 Process Emission details and mitigation measures







5 Hydrogen 16 Diffused by using Nitrogen through Flame arrestor





In order to minimize the air pollution, unit will develop greenbelt in and around

its premises.

ODOR CONTROL

The chance of odours within premises is mainly due to

Raw materials

Storage / Handling

Transportation of raw materials

Process

Raw materials transportation

During reaction

Drying



ETP Operations

Storage / Handling

Storage

Industry will provide adequate and proper storage facilities for all the raw

materials and finished products.

Corrosive substances will be stored away from the moisture.

Solid raw material will be stored in covered area and Liquid raw material will

be stored in closed Horizontal / Vertical tanks.

Hazardous chemicals and solid wastes will be stored away from other plant

activities.

The storage yard of chemicals will be isolated and it will be equipped with all

necessary measures to control odours.

Handling

All the raw materials and finished products will be handled as per the standard

practice.

For proper handling, company will adapt good housekeeping technology to

entire shed.

To avoid any leakage or spillage of chemicals from all storage tanks, third

party will inspects transfer lines, valves, fittings and every joint periodically.

Transportation of Raw materials

All the necessary precautions will be taken while carrying out transport of the

above materials as per the Hazardous Rules of transportation.

The vehicles for transportation of raw materials and products will be parked at

specified loading facilities where there will be a provision of fire extinguishers.

The finished product will be transported by road, rail and ship route in closed

containers.

Other sources of odour nuisance are as follows

Leaks from pressurized process equipment generally occur through valves, pipe

connection, mechanical seals or related equipment.



Control measures

To minimize & control leaks at process facilities operators carry out regular

leak detection test and repair activities.

Routine inspections of process equipment with gas detectors can be used to

identify leaks & estimate the leak rate in order to decide an appropriate

corrective action.

Proper routine maintenance of equipment reduces the likelihood of leaks.

Solvents will be transferred through the closed pipe line system.

Cleaner production practices

Process vessels:

Liquid raw material will be charged by pumping and closed loops and dosing

will be done by metering system to avoid odour.

Double mechanical seals will be provided to the process vessels having

agitator for reduction of odour and leakages.

Storage tanks

Storage tanks for products as well as raw materials will be fitted with

appropriate control devices [Condensers with chilled water circulation

systems] to avoid possible odours / leakages.

House keeping

Keep work areas clean.

Keep aisles clear.

Keep exits and entrances clear.

Use proper waste collection containers.

Cleanup spills and leaks off’s any type quickly and properly.

Follow up preventive predictive maintenance.

4.7 WATER ENVIRONMENT

With respect to water environment; three aspects are considered in EIA, availability

& Requirement of fresh water, Wastewater generation and its disposal.



Fresh Water Requirement

The total water requirement for the proposed project is 134.13 KLD. Water

requirement of unit is met through Ground water.

Waste water generation

Total effluent generation is 52.86 KLD, which is from process, scrubbers, boiler,

cooling towers and washing activities. The HTDS waste water of 19.18 KLD from

Process after neutralization taken for treatment in stripper followed by MEE and

ATFD. LTDS waste water of 33.68 KLD including domestic sewage, floor Washes.

Disposal of Effluent – ZLD System

Utilities waste water taken along with Vapour Condensate from MEE & ATFD for

Biological Effluent Treatment plant. Treated effluent from ETP sent to RO and RO

permeate water is recycled and RO rejects are sent to MEE followed by ATFD for

evaporation. Evaporation salts collected and sent to TSDF. MEE & ATFD vapour

condensate reused along with RO permeate.

MITIGATION MEASURES

Effluent generated in the plant will be treated in Proposed ZLD system.

The industry is proposing to install a MEE System with 40 KLD capacity,

Biological Treatment system of 55 KLD and RO system with 50 KLD

capacities for treatment of 52.86 KLD effluents generated from plant

operations.

Total Water requirement is 134.13 KLD out of which 43.50 KLD recycled

water recovered from ZLD system. The fresh water of 90.63 KLD will be met

from Ground Water source.

The leakages of oil spills from machinery shall be collected in leak proof

barrels and then disposed off to SPCB authorized dealers.

The groundwater levels need to be monitored with setting up of piezometers

in the core and buffer zone.

Unit is proposed to recharge ground water through roof water harvesting pits

in the project area and rain water harvesting pits outside plant area wherever

possible to balance the water table.

Minimization of water use providing drip system for gardening.



Use of high-pressure hoses for cleaning the floor and process equipment to

reduce the amount of wastewater generated during washings.

Conjunctive use of groundwater.

4.8 NOISE ENVIRONMENT

PREDICTION OF IMPACT

Identification of potential impacts on noise environment from the proposed project is

as important as other components of the environment. The main sources of noise

pollution are Boiler, Reactors, DG Set, Air compressors, and other Noise generating

units. Vehicular movements during operation phase for loading / unloading of raw

materials and finished products and transporting activity may also increase noise

level. Noise levels in the ambient air are well within the permissible limits given by

the National Ambient Noise level standards as confirmed during baseline study. Leq

values of the noise levels within the plant premises will be kept less than 75 – 70 db

[A] [during day time and night time] which will be within the permissible limit.

MITIGATION MEASURES

To minimize the noise pollution the unit proposes the following noise control

measures,

Noise suppression measures such as enclosures, exhaust mufflers, buffers

and / or abatement measures that will be implemented.

Employees will be provided with earplugs or earmuffs.

Extensive oiling, lubrication and preventive maintenance will be carried out for

the machineries and equipments to reduce noise generation.

Green Belt Development.

4.9. LAND/ SOIL ENVIRONMENT

IDENTIFICATION OF IMPACTS

Infrastructural development for the proposed project as well as subsequent

developments in the nearby area may change the land use pattern of area.

The impact on land and soil environment may be due to effluent disposal, chemical

and hazardous waste storage & handling. Spillage of chemicals during loading,

unloading and transfer, leakage of pumps, flange leakage in pipelines may create

soil/land contamination.



PREDICTION OF IMPACTS

The Proposed project will be carried out within the acquired land premises; there

will not be any change in land use pattern, forest cover or vegetation in

surrounding area. Moreover, electricity, water, roads, all basic amenities and

infrastructure are already available in the area.

There will not be any disposal of untreated effluent on land. Industrial wastewater

will be properly treated and reuse in various activities within the premises.

Spillage of chemicals during loading, unloading and transfer, leakage of pumps,

flange leakage in pipelines may create soil/land contamination. However, the

regular maintenance of pumps and flange connections in the pipelines will be

carried out and proper care will be taken while loading, unloading and transfer of

materials to avoid any soil/land contamination.

MITIGATION MEASURES

During operational phase, the chances of any enhanced soil erosion are not

anticipated. But improper disposal of toxic wastes and accidental spillages of

toxic chemicals can pose a serious threat to the soil, ground and surface waters.

But the chances of such events cannot be quantified and predicted. Since the

industry is expected all rules and regulations relating to the use, handling and

disposal of all toxic and hazardous chemicals, no additional safety methods are

required especially to prevent contamination of soil.

Liberal use of locally available farmyard manure will be used for the plants in the

greenbelt and block plantations for improving the productivity, fertility and health

of soils.

In case of any spillage, the same will be collected and treated in ETP. The unit

will provide an adequate designated storage area with impervious flooring system

and roof cover with leachate collection system for the storage of hazardous

wastes.

Leachate, if any will be collected and treated in ETP. Thus, there will not be any

chances of contamination of soil due to the storage of chemicals and hazardous

waste.

The hazardous waste generated will be stored and handle as per the Hazardous

Wastes (Management, Handling and Transboundary Movement) Rules, 2016



The project does not have any impact on the soils beyond the boundaries of the

project site since it is a zero liquid discharge unit. Physicochemical characteristics

of the soil samples obtained from 7 areas in the buffer zone and one from the

project site reveals that all basically sandy loams.

4.10. IMPACT OF SOLID WASTE

The details of hazardous waste to be generated from the proposed project, is

mentioned at Chapter - 2. The current practice of storage of generated hazardous

waste, in a closed room having an impervious bottom, and disposed of as per the

prescribed guidelines will be continued for the generation of hazardous waste.

Hence, the impact due to the same will be negligible as the handling of hazardous

waste to be generated will be disposed as per guidelines. The details of

solid/Hazardous waste details are shown in below Table. The ash from boilers will be

used in the brick manufacturing. The ash of 0.5 µm to 45 µm will be used in the

cement manufacturing as a filler material, stabilization of soft soils, mineral filler in

asphaltic concrete, floor and metal castings etc.

MITIGATION MEASURES

To reduce the quantity of solid / hazardous waste generation as well as possible

contamination of land (soil) due to spillages / leaks from the plant operations,

following

Mitigation measures can be implemented:

There will not be any leakages / spillage from the raw-materials storage and

from the storage of generated effluent from the project.

The generated Hazardous waste will be stored on floor with suitable packing

and this dedicated area will be covered with the roof.

The records on quantity of hazardous waste generation and disposal will be

maintained for each category and possibilities will be explored for

minimization and reuse.

Classification of waste, Collection, Storage, Transportation, & disposed/sale

to authorized recycler or re-user.

Data Management and Reporting

Personnel Training



Solid/Hazardous Waste Generation and Disposal mode

Table No.4.8 Hazardous & Solid Waste Disposal Details




1406

Sent to Cement Industries 2 Spent Carbon 71



380


6 ETP Sludge 350

Sent to TSDF 7 Inorganic waste 504

8 MEE Salts 2868




Solid Waste Details


4.11. IMPACTS ON ECOLOGY

Prediction of impacts is based both on the direct and indirect; short-term as well as

long-term; irreversible and irreversible impacts that are most likely to occur owing to

the industrial activity during establishment and operation. The ecological factors that

are considered most significant as far as the impact on flora and fauna are

concerned:

1. Whether there shall be any reduction in species diversity.

2. Whether there shall be any habitat loss or fragmentation.

3. Whether there shall be any risk or threat to the rare or endangered or

endemic or threatened (REET) species.

4. Whether there shall be any impairment of ecological functions such as (i)

disruption of food chains, (ii) decline in species population and or (iii)

alterations in predator-prey relationships.



NEGATIVE IMPACTS

As there is change in the land use and land cover on account of the proposed

project, the proposed action is not going to have any direct and significant negative

impacts of flora and fauna or biodiversity.

MOST PROBABLE SCENARIO

As stated earlier, it is a new project there will be change in the land use and land

cover within the project site. No damage is going to be done to the existing green

cover within the project site. Except for a few weeds, there are only cultivated plants

and no RET species in the core area. No species is going to be lost on account of

the proposed project. No direct or indirect damage is expected to the flora and fauna

of the buffer zone. Further, as there are no rare or endangered or endemic or

threatened (REET) species, the project does not pose any threat to the flora and

fauna of the study area. As the industry is required to operate and maintain the

emissions and effluents within the limits specified by the CPCB / SPCB, the effects

of the industry on the flora and fauna of the buffer zone may be negligible. Neither

the storm water nor the effluent water nor any other kind of rain or waste water from

the industry shall get in to the drinking water resources.

MITIGATION MEASURES

Extensive plantation and green area development of 3.37 Acres is planned in the

proposed project along with landscaping. This is hereby ensured that the mostly

indigenous/local plants will be planted all around the periphery of the project area

and along the compound wall sides. Plantations would be of large leaf trees that

provide adequate shade and are semi evergreen to evergreen. Various native and

indigenous trees would be planted for mitigation purpose

4.12. IMPACTS ON SOCIO- ECONOMY

During the erection phase short term direct or indirect employment will be

generated. Project Proponent shall give first preference to the Local people wherever

found suitable for all the jobs in the plant operations. Economic status of the local

people will improve due to the increased employment & business opportunities,

thereby, making a positive impact to the Local Economy. Educational, medical and



housing facilities in the study area will considerably improve. Thus, the proposed

project will have significant positive impact on the socio-economic environment.

MITIGATION MEASURES

Due to proposed activity the employment generation will be around 100

persons including, skilled, semi-skilled & unskilled labour and office staff.

Local qualified personnel can be employed.

Under CSR & CER Budget, the proponent has allotted 54 lakhs to take up

Environment & welfare activities.

4.13. IMPACTS ON HYDROLOGY & GEOLOGY

The generation of ash from the industry will have sedimentation affect over

the wind ward side on the soil regime as well as the buffer zone over a period

of time affecting the Green cover/ plantation thereby affecting the growth of

plants / crops.

The chemically loaded waste water leakage from the industry will adversely

affect the soil, surface and groundwater.

MITIGATION MEASURES

Ash generation and storage will be monitored closely to avoid leakages and

will be disposed safely to the brick manufacturing industries and infrastructure

projects.

The ash spreading in and around the plant will be avoided by storing under

closed conditions at dedicated place till it is disposed to users. The prevention

suggested is not to allow the waste water leakage from the industry by

implementing proper storage tanks for wastewater collection and ZLD system.

ANALYSIS OF

ALTERNATIVES

(TECHNOLOGY & SITE)

CHAPTER -V


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter - V Page 222

CHAPTER – V

ANALYSIS OF ALTERNATIVES

(TECHNOLOGY & SITE)

5. ANALYSIS OF ALTERNATIVES

This chapter deals with the criteria for site selection and process technology in the

proposed project by assessment of alternatives and comprehensive comparison of all

potential impacts, both direct and indirect and cumulative, on the environment. The goal

of evaluating alternatives is to find the most effective way of meeting the need and

purpose of the proposal.

5.1. SITE SELECTION CRITERIA

SITE LOCATION: To establish a Bulk drugs & Intermediates manufacturing, the site is

selected at Sy No: 290 & Parts, Dondapadu (V), Chinthalapalem (M), Suryapet District,

Telangana state based on these factors Practicability, Feasibility, Relevance,

Reasonable & Viability.

TABLE 5.1: SITE DESCRIPTION



Climatic Conditions

Annual Max Temp is 44.9 0C Annual Min Temp is 15.4 0C Normal Annual Rainfall is 750.7 mm (Source: IMD Climatalogical Normals, Nandigama 1981 - 2010)





National Highway Railway station Airport

National Highway No. 9 – 16 km (ENE) (Hyderabad – Vijayawa da Road) Motumari Railway Station – 33 km (ENE) Vijayawada Airport – 87 km (ESE)

Interstate Boundary Telangana State – Andhra Pradesh Interstate Boundary – 400 meters (NE)


Water Bodies within 10 km radius Krishna River – 2.5 km (ESE) Palleru River – 5.5 km (E)



The proposed project site is identified based on the following considerations:

Land acquired for proposed Project is 9.0 Acres (36414 Sq. m), topographically

the area is generally plain, with gentle slope.

The area is not covered by any notified forests.

Proximity of National Highways and railways stations, for transport of raw

materials and manufactured products.

Availability of infrastructure facilities.

Well connected road networks.

The location of the site have distinct advantages such as accessibility to Road, Rail,

Electricity, Ground water and other facilities which are adequate for the proposed

project and hence, no alternate sites were considered.

5.2. SELECTION OF PROCESS TECHNOLOGY

Proposed to manufacture different types of bulk drugs & intermediates.

All the products will be manufactured on a batch basis.

The products are categorized on similarity in process or therapeutic usage.

Bulk Drugs substances typically consist of structurally complex organic chemical

compounds which are manufactured via a series of intermediate steps and

reactions under precise process conditions.

The drug intermediates are manufactured by:

Chemical synthesis;

Pulichintala Dam – 5.9 km (S) Water body near Jaggayyapet – 8.3 km (NE) Water body near Ramapuram – 8.0 km (WNW)


Budavada R.F- 2.8 km (N) Balusupadu R.F – 6.0 km (N) Jaggayyapeta Extension R.F – 5.8 km (E) Kuntimadi R.F- 5.2 km (ESE) Ginjupalle R.F- 6.4 km (SE) Venkatayapalem Extension R.F- 6.0km (SE) Venkatayapalem R.F- 5.8 km (SSE) Nemalipuri R.F – 7.6 km (SSW) Chintapalem R.F – 7.6 km(SSW)



Isolation / recovery from natural sources; and /or

Combination of above.

In the proposed project, resource availability may limit the range of alternatives in a

particular context. Bulk drugs & Intermediates will be manufactured using proven

Chemical synthesis technology; hence no alternative technology has been analyzed

thus, no new or untested technology will be used.

ENVIRONMENTAL

MONITORING PROGRAM

CHAPTER -VI


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter – VI Page 225

CHAPTER – VI

ENVIRONMENTAL MONITORING PROGRAM

6.1. INTRODUCTION

Regular monitoring of environmental parameters is of immense importance to assess

the status of environment during plant in operation. With the knowledge of baseline

conditions, the monitoring programme will serve as an indicator for any deterioration in

environmental quality due to operation of the expansion project, to enable taking up

suitable mitigative steps in time to safeguard the environment. Monitoring is as

important as that of control of pollution since efficiency of control measures can only be

determined by monitoring.

The baseline study is carried out for post monsoon season. Hence, post project

monitoring programme of the environmental parameters is essential to take into account

the changes in the environmental quality to ascertain the following:

State of Pollution within the plant site and in its vicinity.

Generate data for predictive or corrective purpose in respect of pollution.

Examine the efficiency of air pollution control system adopted at the site.

To assess environmental impacts.

Monitoring will be carried out at the site as per the norms of CPCB.

Environmental Monitoring Programme will be conducted for various environmental

components as per conditions stipulated in Environmental Clearance Letter issued by

MoEF&CC & Consent to Operate issued by SPCB. Six monthly compliance reports will

be submitted on regular basis, to MoEF&CC, Regional Office, Nalgonda on 1st of June

& 1st of December. Quarterly compliance Report for conditions stipulated in Consent to

Operate will be submitted to SPCB on regular basis.

6.2. ENVIRONMENTAL MANAGEMENT SYSTEM

In order to maintain the environmental quality within the standards, regular monitoring of

various environmental components is necessary. The company will establish full-



fledged environmental management cell (EMC) reporting directly to Plant Manager for

environmental monitoring and control. The EMC team will takes care of pollution

monitoring aspects and implementation of control measures.

A group of qualified and efficient engineers with technicians is deputed for maintenance,

up keeping and monitoring the pollution control equipment, to keep them in working at

the best of their efficiencies. For effective and consistent functioning of the plant, the

EMS at the site will be strengthened further with the following:

Environmental management cell covering EHS (Environment, Health & Safety)

team


Personnel Training

Regular Environmental Audits and Corrective Action Plan

Documentation – Standard operating procedures, Environmental Management

plans and other records

6.3. ENVIRONMENTAL MANAGEMENT CELL RESPONSIBILITIES

It is necessary to have a permanent organizational set up charged with the task of

ensuring its effective implementation of mitigation measures and to conduct

environmental monitoring. The major duties and responsibilities of Environmental

Management Cell will be as under:

To implement the Environmental Management Plan (EMP)

To ensure regulatory compliance with all relevant rules and regulations

To ensure regular operation and maintenance of pollution control devices

To minimize environmental impacts of operations by strict adherence to the EMP

To initiate environmental monitoring as per approved schedule

Review and interpretation of monitored results and corrective measures with

reference to prescribed standards

Maintain documentation of good environmental practices and applicable

environmental laws for ready reference.



Maintain environment related records.

Coordination with regulatory agencies, external consultants, monitoring

laboratories.

Organising meetings of the Environmental Management Committee and

reporting to the committee.

To improve the capacity building of the Environment Department, as a part of the

management, a separate division will be created under the leadership of Plant Manager,

who is assisted by EHS - Manager will be working for day to day operation of

environmental management systems with documentation, procedures & Compliances.

All executives/Supervisors and workmen/Helpers will be responsible for the operations.

The Organizational Structure of Environmental Health and Safety is presented in Fig.

6.1.

Any non-compliances/violations of serious nature will be addressed by the Plant general

manager in consultation with the directly involved officials and will report to the Board of

Directors of the company. The primary focus is to comply with the regulations and work

out on action taken report to be placed before the Board of Directors. Similarly a

preventive action for non-recurrence of such violations/non-compliances will also be

worked out and strict monitoring will be done by the Management for implementation of

the same



Fig. 6.1: Organisational Structure of Environment Health & Safety

6.4. ENVIRONMENTAL MONITORING AND REPORTING PROCEDURE

Monitoring may take the form of direct measurement and recording of quantitative

information, such as concentrations of discharges, emissions and wastes, for

measurement against corporate or statutory standards, consent limits or targets. It may

also require measurement of ambient environmental quality in the vicinity of a site using

ecological/biological, physical and chemical indicators. Monitoring may include

socioeconomic interaction, through local liaison activities or even assessment of

complaints. Monitoring will also be required to meet compliance with statutory and

corporate requirements. Finally, monitoring results will provide the basis for auditing.

6.4.1. OBJECTIVES OF MONITORING

The objectives of environmental post-project monitoring are to

Verify effectiveness of planning decisions

Measure effectiveness of operational procedures

Confirm statutory and corporate compliance and

Identify unexpected changes.



6.4.2. MONITORING SCHEDULE FOR CONSTRUCTION AND OPERATION PHASES

Environmental monitoring schedules of SGR Laboratories Pvt. Ltd. are prepared

covering various phases of project advancement, such as construction and operation

phases.

Construction Phase

The proposed project envisages setting up of buildings and machinery, establishment of

production and storage facilities. The construction activities are expected to last for

about one year. As there are no major construction activities for the plant, simple and

generic environmental monitoring measures that need to be undertaken during project

construction stage.

Operation Phase

During operation stage of the project, air emissions from process areas, Boilers and DG

set. Full-fledged Effluent treatment plant with ZLD Scheme operates for water recovery

and reuse, hazardous and nonhazardous waste generation is envisaged. The following

attributes which meet regular monitoring based on the environmental setting and nature

of project activities are listed below:

Source emissions and ambient air quality.

Work zone monitoring for VOCs/ solvents in air.

Groundwater levels and ground water quality in bore wells.

Raw and ETP effluent quality.

Hazardous and solid waste characterization (process hazardous waste, ash,

ETP sludge, used and waste oils).

Soil quality.

Noise levels (equipment and machinery noise levels, occupational exposures

and ambient noise levels) and

Ecological preservation and afforestation.

Monitoring Schedule: Details of the Post Project Environmental Monitoring schedule,

which will be undertaken for various environmental components are detailed below:



Table 6.1: Post Project Environmental Monitoring schedule details

Sl. No. Description Frequency of Monitoring

1 Ambient Air Quality at Plant site Once in a month

2 Water Quality Monthly Basis

3 Noise Level Monitoring Monthly Basis

4 Soil Quality Once in six months

Methodology Adopted: Post project monitoring will be carried out as per conditions

stipulated in Environmental Clearance Letter issued by MoEF&CC, Consent order

issued by concerned State PCB as well as according to CPCB guidelines. The plant site

is considered as core zone and the area lying within 10 km radius from the plant site is

considered to be the buffer zone. In the Buffer zone slight impact may be observed and

that too is occasional.

Table No. 6.2 Environmental Monitoring Plan during Operation Phase

Sl. No Potential Impact Action to be

Followed Parameters for

Monitoring Frequency of

Monitoring

1 Air Emissions

Stack emissions from process stacks to be optimized and monitored

Process emissions (HCl, SO2, NH3, as applicable)

Monthly with recommended methods of CPCB

Stack emissions from Boilers, DG sets to be monitored

Emissions (PM, SO2, HC, NOx)

Monthly with recommended methods of CPCB

Ambient air quality within the plant premises of the proposed expansion unit and nearby habitations to be monitored. Exhaust from vehicles to be minimized by use of fuel efficient vehicles and well maintained vehicles having PUC certificate.

Ambient air quality will conform to the standards for NAAQ parameters (MoEF circular dated 16-11- 2009) and HCl, Cl2 and HC Vehicle logs to be maintained

Online continuous AAQ one station and Monthly in Industry and nearby habitants with recommended methods of CPCB.

Vehicle trips to be minimized to the extent possible

Vehicle logs Daily records






Monitoring

2 Noise Levels

Noise generated from operation of boiler/cooling towers to be optimized and monitored (3 locations within plant and 2 locations outside plant) Noise generated from operation of DG sets to be optimized and monitored

Noise Level recording; Leq (night), Leq (day), Leq (dn)

Regular and Monthly

Generation of vehicular noise

Vehicle Maintenance records

Monthly

3 Waste water Discharge

Segregated effluent Stream wise (3 streams)

ETP performance will be monitored for raw and treated effluent characteristics for reuse of treated effluent. Basic parameters like pH, TSS, TDS, COD, Oil & grease

Daily with internal lab and monthly from authorized lab

In-house ETP treated Effluents reuse in Cooling Towers

pH, TDS, COD and Temperature etc.

Daily monitoring at In- house Laboratory for treated effluent

4 Drainage and

effluent Management

Ensure drainage system and specific design measures are working effectively.

Visual inspection of drainage and records thereof

Daily

5 Water Quality

Surface and Groundwater quality surrounding plant site

Comprehensive monitoring as per BIS 10500-2012.

Quarterly

6 Work zone air quality

Contaminants such as VOCs to be reduced by providing adequate ventilation

Indoor monitoring of VOCs.

On Daily Basis

7 Hazardous / Solid Waste

Implement waste management plan

Records of solid waste generation,

Regular Basis during operation






Monitoring

Management that identifies and characterizes every waste arising associated with proposed activities and which identifies the procedures for collection, handling & disposal of each waste arising.

storage and disposal

phase

8 Soil quality

3 locations within plant site, solid waste storage area, near production block and ETP area

Physico-chemical parameters and Heavy metals.

On regular basis (Once in six Months)

9 Occupational

Health

Employees and migrant labour health check -up

All relevant parameters including HIV

Once in a Year

Comprehensive Pre-employment medical checkup for all employees.

Medical examination will be done for all the employees once in a year.

Tie up with local hospitals and Govt. health monitoring system will be engaged during emergency.

Dispensary and ESI facility will be provided to all workers as applicable.

All safety gears will be provided to workers and care will be taken by Environmental Management Cell (EMC) that these are used properly by them. All safety norms will be followed.

6.5. LOCATION OF MONITORING STATIONS

Location of the monitoring stations will be selected on the basis of prevailing micro –

meteorological conditions of the area like; Wind direction & wind speed, Relative

Humidity, Temperature. Post project air quality monitoring will be carried out at plant site

and 2 locations (one each in upwind and downwind direction) to asses ambient air

quality of the area. Major surface water body lies within 10 km area of plant site and

ground water quality monitoring will be carried out. Regular monitoring of noise will be

done to control noise levels at plant site. Soil quality will be tested of the plant site area



regularly to keep check on any leakage in storing hazardous waste. Locations for the

post project monitoring will be as under:

Table 6.3: Details of Post Project Monitoring Locations

S. No.

Description Location of Monitoring

1 Ambient Air Quality Plant site, Villages in upwind & downwind direction (with Max. Ground level concentration) from the plant site

2 Noise Level Monitoring Plant Boundary, High Noise generating areas within the plant boundary

3 Water Quality From Nearby Surface water Source and Ground Water Source

4 Soil Quality At plant Site and Nearby area

6.6. MONITORING AND DATA ANALYSIS

6.6.1. AIR QUALITY MONITORING AND DATA ANALYSIS

Stack Monitoring: The emissions from all the stacks will be monitored for exit gas

temperature, velocity and pollutant concentrations. Any deviation from the design

criteria will be thoroughly examined and appropriate correction will be initiated. Air

blowers will be checked for any drop in exit gas velocity. The monitoring will be done by

authorised laboratory and test result will be submitted to the SPCB.

Work Zone Monitoring: The concentration of air borne pollutants in the

workspace/work zone environment will be monitored periodically. If concentrations

higher than threshold limits are observed, the source of fugitive emissions will be

identified and necessary measures taken. In addition, industry will continue to monitor

the VOC in all process & storage areas on regular basis. In case, the levels are high,

suitable measures as detailed in EMP will be implemented.

Ambient Air Quality Monitoring: The concentrations of PM, SO2, NOX, NH3, CO and

HC in the ambient air will be monitored at regular intervals. In case of any excess

concentration in the ambient air quality due to the proposed production enhancement,

proponent will take necessary action and follow the air pollution control measures.

Greenbelt will further be developed for minimising dust propagation. The ambient air

quality data will be transferred and processed in a centralised computer facility



equipped with required software. Trend and statistical analysis will be carried out as per

the CPCB guidelines.

6.6.2. WATER AND WASTEWATER QUALITY MONITORING AND DATA ANALYSIS

To ensure a strict control over the water consumption, flow meters will be installed for

existing and proposed facilities for all major inlets in expansion. All leakages will be

identified and rectified. In addition, periodic water audits will be conducted to explore

possibility of water conservation.

Industry will analyse the basic parameters and the procedures prescribed in "Standard

Methods for Examination of Water and Wastewater" prepared and published jointly by

American Public Health Association (APHA), American Water Works Association

(AWWA) will be followed for all the parameters of monitoring. As per the CPCB

guidelines, industry will be installed the online sensors in the treated effluent for pH,

Conductivity and DO with night vision cameras.

Surface and Groundwater Monitoring: The monitoring of Surface and groundwater is

the most important tool to know the variations from the baseline study. This is

indispensable as it provides detection of the presence of waste constituents in ground

water in case of leachate migration. In this project, chances are very less for leachate

as the total effluent is segregated and is sent to ETP – ZLD and the treated effluent will

be reused in cooling tower. The water samples from the nearby surface water bodies

and bore wells will be analysed for relevant parameters as per monitoring program.

Records of analysis will be documented.

Monitoring of Wastewater Streams: All the segregated wastewater streams will be

regularly measured for physic - chemical, nutrient and demand parameters. The

monitoring will be carried out from stream wise raw wastewater, raw and treated effluent

characteristics of ETPs before recycling to utilities. These data will be documented and

compared against the design performance values of ETPs for necessary corrective

action.



The ETP will be operated and maintained by existing & additional skilled and dedicated

personnel. Daily log sheets for no. of hours of the ETP operation, chemicals, electrical

and steam consumption; effluent monitored parameters with their results, etc. will

continue to be maintained.

6.6.3. NOISE LEVELS

Noise levels in the work zone environment such as boiler house, cooling tower area,

and DG house will be monitored. The frequency will be once in a month in the work

zone. Audiometric tests will be conducted periodically for the employees working close

to the high noise sources.

6.6.4. SOIL QUALITY

Soil quality will be tested for the parameters given in schedule for every six months.

6.7. REPORTING SCHEDULES OF THE MONITORING DATA

It is proposed that voluntary reporting of environmental performance with reference to

the EMP will be undertaken. The environmental monitoring department will co-ordinate

all monitoring programmes at site and data thus generated will be regularly furnished to

the State regulatory agency. The frequency of reporting will be on monthly basis to the

local state PCB officials and six monthly reports to Regional Office of MoEF&CC. The

Environmental Audit reports will be prepared for the entire year of operations and will be

regularly submitted to regulatory authorities in Form V Environmental Statement.

6.8. ENVIRONMENTAL LABORATORY

Environmental laboratory will be well-equipped analytical instruments and consumable

items for monitoring of environmental parameters at the site. Alternatively, monitoring

will be continued to be outsourced to a recognized/approved laboratory. The equipment

and consumable items will be made available at the site for environmental monitoring.

The sampling is done as per the standard procedures laid down by IS: 2488. The

equipment’s will be in the Environmental Laboratory are Heating Mantle, Digital

conductivity meter, Digital pH Meter, COD Digestion Apparatus, BOD Incubator, Hot air

oven, Muffle Furnace, Thermometer, Microprocessor based conductivity meter,



Microprocessor based pH Stat Analyzer, Electronic Balance, HOT Plate, Mechanical

Balance, Hand Held DO meter, Hand Held Turbidity meter, Magnetic Stirrer and

consumables, chemicals and Glassware.

6.8.1. AIR QUALITY AND METEOROLOGY

Proposed: Manual AAQ monitoring stations – 3 Nos., on monthly basis third party

monitoring will be done by NABL / MoEF&CC authorised laboratory and the test report

will be verified for any deviation in air quality standards for corrective action and the test

reports will be submitted to the respective SPCB.

6.9. OCCUPATIONAL SAFETY AND HEALTH ASPECTS

All the preventive and corrective actions of environmental impacts to protect the health

of all the employees from any possible occupational health problems, the periodical

medical and health checkups of all the employees will be done to assess the any

occupational health problems.

ADDITIONAL STUDIES

CHAPTER -VII


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter - VII Page 237

CHAPTER – VII

ADDITIONAL STUDIES

[RISK ASSESSMENT & DISASTER MANAGEMENT]

SGR Laboratories Pvt. Ltd. is proposed to manufacture Bulk Drugs & Intermediates

at survey No. 290 & Parts, Dondapadu (V), Chinthalapalem (M), Suryapet District,

Telangana State and is covered under Category- A of the EIA Notification – 2006.

Public Consultation is required for this project.

7.1 ADDITIONAL STUDIES

In order to support the environment impact assessment and environment

management plan, following additional studies have been included in this report.

Risk Assessment

Disaster management plan

Occupational Health

7.1.1 SCOPE OF THIS STUDY

The QRA (Quantitative Risk Assessment) study in this report has been conducted

considering the Terms of References (TORs) given for Environment Clearance (EC).

The study has been carried out with a view to comply TOR points with respect to

Risk assessment.

7.1.2 Methodology:

The following parameters are considered to prepare Quantitative Risk Assessment.

1. Discussions were held with Plant officials on proposed individual safety

systems of plant operations.

2. Hazard Identification exercise in coordination with plant officials was

conducted taking into consideration the proposed storage of Hazardous

Chemicals/Solvents, operating parameters and proposed safety systems.

3. Containment failure scenarios related to flammable chemicals & hazardous

chemicals have been considered for Risk Assessment and consequences in

detail. Thus, this study is mainly oriented towards acute risks rather than

chronic risks.

4. Discussed on proposed Raw materials Hazards and their Risks in handling.



7.2 Risk Assessment

SGR laboratories Pvt. Ltd. will handle various chemicals, some of which are

hazardous in nature by virtue of their intrinsic chemical properties or their operating

temperatures or pressures or a combination of them. Fire, explosion, toxic release or

combinations of them are the hazards associated with industrial plants using

hazardous chemicals. More comprehensive and systematic methods have been

adopted in Hazard Identification and Quantitative Risk Assessment to improve upon

the integrity, reliability and safety of the plants. The same has been discussed in

detail under their respective headings.

7.2.1 Objectives of Risk Assessment

Risk analysis follows an extensive hazard analysis. It involves the identification and

assessment of risks the neighboring populations are exposed to as a result of

hazards present. This requires a thorough knowledge of failure probability, credible

accident scenario, vulnerability of population etc., much of this information is difficult

to get or generate. Consequently, the risk analysis is often confined to maximum

credible accident studies.

The risk assessment process is primarily based on likelihood of occurrence of the

risks identified and their possible hazard consequences particularly being evaluated

through hypothetical accident scenarios. With respect to the proposed project, major

risks are leaks from storage tanks, rupture of Pipelines, Spillages from containers

during transfer operations and Storage in the Ware house have been assessed. Risk

associated with the flammable chemicals storages have been determined semi-

quantitatively as the product of likelihood/probability and severity/consequence by

using order of magnitude data (risk ranking = severity/consequence factor X

likelihood/probability factor). Significance of such project related risks have been

established through their classification as high, medium, low, very low depending

upon risk ranking.

It provides basis for:

The type and nature of its on-site and off-site emergency plan

The types of safety measures required



7.2.2 IDENTIFICATION OF HAZARDS

Hazard identification is carried out to ascertain the controls required and

available in order to mitigate the risk of exposure to the hazards. This would

substantially help in overcoming costly errors and prolonged delays that may

be caused due to the design changes that may be required on a later date.

Hazard assessment in the proposed plant is carried out examining the Liquid

and solid chemicals storage in the ware house, production operations of toxic

chemicals such as Thionyl chloride and solid chemicals such as Sodium

borohydride, Potassium hydroxide, Raney Nickel and Storage of Flammable

liquid chemicals such as Methanol, Toluene, Acetone, Ethyl Acetate, IPA, n-

hexane, in bulk quantities in plant premises, locations to find out the

adequate facilities in place to overcome the Risks of exposure to the Hazards.

Following are the Hazards identified in proposed plant activities:

Fire Hazards due to Flammable chemicals leakage from storage tanks, pipe

line ruptures during transfer of material which may get ignited due to any

spark.

Fire Hazard due to improper earthing of storage tanks and material transfer

lines

Fire hazard due to leakage of flammable chemicals from transfer pumps gland

leaks.

Spillage/Leakage of Hazardous chemicals – Solvents, Acetic acid, HCl,

Thionyl chloride which leads to Air pollution, Water pollution and Soil pollution

Hydrogen gas explosion at high pressure during Lopinavir and Ritonavir

production.

The exposure to hazards depends upon the concentration of hazard, Frequency and

duration. The exposure to hazard could be controlled by reducing either the

concentration of hazard, frequency or duration.

After a critical analysis of the chemicals propose to use, stored and for products to

manufacture a defined safe operating procedures will be in place with safety and

mitigation measures to overcome the hazards.

The exposure to the hazard could be controlled by implementing the following:

Engineering controls at the source



Environmental controls that remove the hazard from the environment

Inspection of solvents transfers pipelines & Hydrogen gas conveying lines

once in a month.

Earthing to all storage tanks and providing jumpers to transfer pipe lines to

have continuity of earthing.

Process reactor which is proposing to use for hydrogenation should be kept

away from production block to minimize the effect in case of explosion.

Providing suitable personal protective equipment

Employing experienced trained personnel

All the proposed process reactors will have temperature control and pressure control

system for process as well as suitable Rupture disc followed by a safety valve to

avoid explosion due to excess pressure.

Draft EIA Report SGR Laboratories


TABLE 7.1: AREA WISE IDENTIFIED HAZARDS, PRECAUTIONS PROPOSED WITH MITIGATION MEASURES

S. No.

AREA IDENTIFIED

HAZARD

SEVERITY & NO. OF

PERSONS EXPOSED

PRECAUTIONS PROPOSED MITIGATION MEASURES

1] Raw Material Storage area

Spillage of chemicals

Low to medium & 4 persons

1. Approved layout as per legal

requirements.

2. Flame proof electrical fittings will

be installed

3. Chemicals will be stored in safe

Containers with secondary

containment to prevent spillages.

4. Storage quantity is limited

5. Storage area will be well ventilated

by a forced air ventilation system.

6. Material will be accessed only by

authorized personnel using

mechanized systems

7. Double door entry to ensure a

clean atmosphere.

8. Showers will be provided for

decontamination.

9. Personnel will be provided with full

body protection suits and nose

masks to prevent exposure to

chemicals.

10. Fire hydrant system with hydrant

points with hose reels and nozzles

1. Area will be cordoned off.

2. Information will be passed to

Emergency control center is

informed.

3. Information will be given to the

declarer of emergency on the

scale of Leakage.

4. Emergency Response teams will

be kept on alert for swift response.

5. All hot works being carried out in

the surrounding areas will be

stopped

6. Personnel working in the area will

be evacuated.

7. Spilled powders will be collected

using vacuum cleaners.

8. The spillage will be cleared and

the area is made fit work

9. In case of liquid chemical spillage,

the container will be shifted from

ware house to the outside for

arresting the leakage and

transferring the contents to another



S. No.

AREA IDENTIFIED

HAZARD

SEVERITY & NO. OF

PERSONS EXPOSED


will be installed to mitigate fire

hazards

11. Fire extinguishers will be deployed

adequately

12. Fully fledged medical center will

be arranged

13. Periodical occupational health

checks will be done to personnel

working in the area to Access

health effects, if any.

14. Liquid chemicals such as ,

MIBK,THF and Thionyl chloride

will be stored in dedicated area.

Solid chemicals such as Sodium

borohydride, Sodium hydroxide,

Potassium hydroxide will be stored in

dedicated area.

Solid and liquid chemicals will not be

stored in the same area.

vessel depends on situation.

The area where leakage is occurred

will be neutralized if necessary and

cleaned.

The warehouse will have good

ventilation so as to minimize the

concentration of respective chemical

in the working area.

2] Solvents Storage area

Fire, Flammable area of vapor cloud

Medium to High & 2 persons

1. Storage facility will be provided in

isolated area to have natural

ventilation


2. No Hot work will be carried out in

the vicinity to prevent accidental



S. No.

AREA IDENTIFIED

HAZARD

SEVERITY & NO. OF

PERSONS EXPOSED


2. Flameproof electrical fittings to be

allowed in storage area to prevent

any fire hazard.

3. No electrical gadgets or items

capable of generating static

electric charges will be permitted

in the area.

4. Personnel will be trained about

Do‘s & Don‘ts during emergency.

5. No heat sources will be permitted

near the Facility.

6. Hot work will be controlled through

a work permit system

7. For all storage tanks double

earthing will be arranged

8. Adequate size Dyke wall will be

provided to for containment in

case of leakage of chemical

/solvent.

9. Storage quantity and material will

be handled by trained and

authorized personnel.

10. Mechanical foam type fire & DCP

fire extinguishers will be provided

spread of fire.


be evacuated

4. Emergency control center will be

informed



scale of Leakage of solvent, Fire.


be kept on alert for swift response.

7. The leakage will be cleared and

the area is made fit work

8. In case leakage is found, the

contents will be transferred to a

spare tank or in to HDPE drums.



S. No.

AREA IDENTIFIED

HAZARD

SEVERITY & NO. OF

PERSONS EXPOSED


at all solvent storage tanks

11. Fire hydrant system with hose

reels will be provided in the

solvents storage area.

12. Hydrocarbon detectors will be

provided in the storage tanks area.

13. Flame arrestor will be provided for

each storage tank.

3] Production Block

Spillages / Fire/ Toxic gas release

Low to medium 25 persons


be installed

2. Freight lift will be installed for

movement of material

3. Material will be stored at

production blocks in safe

containers for batch charging

with secondary containment to

prevent Spillages.

4. Earthing and bonding will be

carried out for all reactor vessels

and pipelines

5. Nitrogen lines will be provided to

reaction vessel to create inert

atmosphere inside the reactor to

avoid fire and explosion


2. Power supply will be cut off to the

area to prevent accidental fire.

3. All hot work carried out in the

vicinity will be stopped.


informed.



scale of spillage / fire/Toxic gas

release


be kept on alert for swift

response.


be evacuated.



S. No.

AREA IDENTIFIED

HAZARD

SEVERITY & NO. OF

PERSONS EXPOSED


6. Work permit system will be

implemented for hazard

assessment in case of any hot

work / work at elevated places.

7. Manufacturing area will be

ventilated by a Forced air

ventilation system to prevent

formation of flammable mixture.

8. Fire hydrant system with hydrant

points with hose reels and

nozzles will be installed to

mitigate fire hazards

9. Fire extinguishers will be

deployed adequately

10. Emergency exit door will be

provided to each floor for safe

escape in case of emergency

11. Eye wash fountain / Body shower

will be provided for

decontamination at each floor.

12. Limit switches will be provided for

centrifuges for safe operation.

13. Nitrogen purging will be

arranged for each Centrifuge to

8. Scrubber will be kept in operating

condition with caustic scrubbing

solution

9. Fire hydrant system will be put in

use.

10. If situation beyond control

information will be given to

Inspector of factories, police, fire

department for their assistance.



S. No.

AREA IDENTIFIED

HAZARD

SEVERITY & NO. OF

PERSONS EXPOSED


Production operations

Toxic gases release

25 persons

prevent formation of explosive

flammable mixture.

14. Each reactor will be connected to

a scrubber to neutralize or

decrease the pressure in case

sudden rise in pressure.

Material will be transferred to reactor

by experienced operating personnel

under mild negative pressure to avoid

release of fumes to atmosphere

1. Scrubber will be kept in operating

condition with cooled water

circulation during transfer of the

material.


be kept on alert for swift response



informed



scale of Leakage.

6. Neighboring industries and

statutory authorities will be

informed in case situation is

severe.

4] Boiler House

Fire/ Explosion

Low to medium &

1. All requirements specified under Boiler Act will be followed

1. Shutting down the plant, declaring the emergency.



S. No.

AREA IDENTIFIED

HAZARD

SEVERITY & NO. OF

PERSONS EXPOSED


2 persons 2. All electrical fittings will be of

flame proof Type.

3. Entry will be restricted only to

trained and authorized personnel

to work in the area.

4. Fire extinguishers will be

positioned at different locations in

case of any Emergencies.

5. No material storage will be

permitted in the Area.

6. Auto level controller for Water

and high temperature alarms will

be provided.

7. Water hardness will be checked

on shift wise.

8. Area will be well ventilated and

illuminated for safe working.

9. 24 x 7 manning of the area is

done for monitoring of operation.

10. All maintenance /repair works will

be carried out after issuing work

permits and under constant

supervision of experts.

11. Periodical cleaning of soot in

2. Electrical supply will be isolated.

3. Type of emergency will be

informed to the emergency

declarer/ central authority.

4. Emergency response teams will be

kept on alert for swift action.

5. Movement of personnel and

vehicles will be prohibited.

Adequate no. of Fire hydrant

system will be put in use.



S. No.

AREA IDENTIFIED

HAZARD

SEVERITY & NO. OF

PERSONS EXPOSED


furnace to prevent formation of

explosive mixtures.

12. Checking of boiler internals as

per given schedule to prevent

Accidents.

13. Signage‘s will be displayed to

inform personnel about the

hazards present in the area

5] Diesel Generator

Noise & Fire Low & 1 person

1. Noise abatement through modular

acoustic paneling of D. G. set

2. Secondary containment is done to

prevent Diesel leakage from day

tanks.

3. Adequate no. of fire extinguishers

will be kept to handle emergency.

4. Entry access to the area will be

only for Authorized personnel.

1. Information will be given to

Emergency control center.

2. Power supply will be cut off to the

storage area to prevent

accidental fire.

3. All hot work around the area will

be stopped and the area will be

cordoned off

4. The concerned maintenance

personnel will be carried repairs

to mitigate the leakages.

5. Emergency Response Team will


response.

6. Periodical occupational health

checks will be done to personnel



S. No.

AREA IDENTIFIED

HAZARD

SEVERITY & NO. OF

PERSONS EXPOSED


working in the area to assess

exposure to noise.

6] Electrical sub -station

Electric shock / fire

Low to Medium & 2 persons

1. Layout confirm to legal requirements as per Indian Electrical Rules.

2. Entry will be restricted to licensed and authorized personnel only.

3. Earthing will be provided for leakage of stray currents.

4. Electronic mimic panels will be installed for fault indication at the entry of the sub-station.

5. Insulating rubber mats confirming to IS: 15652- 2006 will be provided in front of all electrical panel boards.

6. Periodical inspection and maintenance will be carried out to ensure good health of the equipment.

7. CO2 / DCP fire extinguishers will be deployed to handle emergency fires



2. Power supply will be cut off from

incoming source.

3. Electricity supply company will be

alerted for cut off power supply in

case of major risks


be stopped and the area is

cordoned off.



to restore normalcy.



response

7] Hazardous waste storage shed

Fire/Leakage

Low to Medium & 1 Person

1. Storage shed will be at an

isolated location.

2. Conditions specified in

hazardous waste Authorization



2. Power supply will be cut off from

incoming source.



S. No.

AREA IDENTIFIED

HAZARD

SEVERITY & NO. OF

PERSONS EXPOSED


issued by SPCB will be

implemented.

3. Compatible wastes will be stored

in separate enclosures

4. Layout provides adequate

ventilation and illumination

5. Secondary containment provided

to prevent leakages / spillages

6. Storage quantity will be limited.

7. Periodical disposal of

accumulated waste will be sent

to authorize landfills.


be installed to prevent fire /

explosion hazards

9. Eye wash / body shower will be

provided for decontamination in

case of spillage on body parts.

10. PPE box will be equipped with

gum boots, splash proof safety

goggles, aprons for use during

handling of chemicals.

11. Access to the area will be

restricted to authorize personnel


be stopped and the area is

cordoned off



to restore normalcy

5. Fire hydrant system will be put in

use



response.

7. Support of external agencies will

be sought in case situation poses

major risks and is not controllable

by in-house infrastructure



S. No.

AREA IDENTIFIED

HAZARD

SEVERITY & NO. OF

PERSONS EXPOSED


only.

12. Fire hydrant point with hose reels

will be provided for fire mitigation



7.3 List of Solvents/Chemicals

Table 7.2: LIST OF SOLVENTS/ CHEMICALS

S. No

NAME OF SOLVENT/CHEMICAL

PHYSICAL STATE

MODE OF STORAGE

MAX. INVENTORY IN

TONS

NATURE OF HAZARD

NFPA RATING

1 Methanol Liquid MS Tank 40 Flammable H : 1 F: 3 R : 0

2 Toluene Liquid MS Tank 40 Flammable H : 2 F: 3 R : 0

3 MDC Liquid MS Tank 20 Harmful H : 2 F: 1 R : 0

4 Acetone Liquid MS Tank 20 Flammable H : 1 F: 3 R : 0

5 Ethyl acetate Liquid MS Tank 10 Flammable H : 1 F: 3 R : 0

6 HCl Liquid PP+FRP Tank 2 Corrosive H:3 F:0 R:1

7 Sulfuric acid Liquid HDPE Carboys 0.5 Corrosive H:3 F:0 R:2

8 Hydrogen Gas Cylinders 50 nos Explosive H:0 F:4 R:0

9 THF Liquid HDPE Drums 5 Flammable H : 2 F: 3 R : 1

10 Thionyl chloride Liquid HDPE Carboys 2 Toxic H:4 F:0 R:2

11 Raney nickel Solid HDPE Carboys 0.1 Flammable H:2 F:4 R:1

12 Sodium borohydride Solid HDPE Carboys 0.3 Flammable H:3 F:4 R:2

13 n-Hexane Liquid HDPE Drums 3 Flammable H:1 F:3 R:0

14 DMF Liquid HDPE Drums 1 Flammable H:1 F:2 R:0

15 Acetic acid Liquid HDPE Drums 0.3 Corrosive H:3 F:2 R:0

16 IPA Liquid MS Tank 20 Flammable H : 1 F: 3 R : 0



7.4 Potential Hazards of solvents and chemicals

Acetone: It is a clear, volatile, flammable liquid. Vapors may form explosive

mixtures with air. Vapors are heavier than air and may travel along the ground to

some distance source of ignition and flash back.

On combustion may emit toxic fumes of carbon monoxide and CO2.

This product causes irritation of eyes, skin, and mucous membranes in case of

contact. It will cause lung damage if swallowed. Do not breathe vapors.

Flash point: -20o C. Boiling point; 56.2o C

Explosive limits: Lower: 2.6%

Upper: 12.8 %

N-Hexane: It is a clear, volatile, highly flammable liquid. Vapors may form explosive

mixture with air. Vapors are heavier than air and may travel along the ground to

some distance source of ignition and flash back. Fire or intense heat may cause

violent rupture of packages. Hazardous combustion products may include carbon

monoxide, carbon dioxide.

Use foam, carbon dioxide or dry chemical. Suppress vapors/mists with a water spray

jet.

In case of spillage soak up with inert absorbent material such as sand, silica gel, saw

dust. Do not use sparking tools. Do not allow product to enter sewer or waterways.

Store in a well-ventilated place to effectively remove and prevent buildup of any

vapors or mists generated from handling of this product.

While handling wear impervious gloves and anti-static protective clothing. For leak,

spills, or other emergency, use full protective equipment.

It is incompatible with oxidizers, halogens, chromates, perchlorates, peroxides.

Flash point: -22o C. Boiling point; 69o C

Explosive limits: Lower: 1.1%

Upper: 7.5 %



Methanol: Extremely flammable and vapor may form ignitable vapor- air mixtures in

storage tanks or other containers. Ignition and busing can release carbon monoxide,

carbon dioxide and non combustible hydrocarbons (Smoke)

Use foam, carbon dioxide or dry chemical. Suppress vapors/mists with a water spray

jet.

While handling wear impervious gloves and anti-static protective clothing. For leak,

spills, or other emergency, use full protective equipment.

Inhalation can Cause dizziness, head ache and nausea, kidney and liver disorder

Flash point: 12o C. Boiling point; 64.5o C

Explosive limits: Lower: 6%

Upper: 36.5 %

Raney nickel catalyst: Keep container tightly closed and to be stored in a cool, well-

ventilated area. Do not allow material to dry. If allowed to dry in air, it turns to red hot

and provides a combustion source for exposed combustible materials.

It should be kept away from incompatibles such as oxidizing agents, combustible

materials, organic materials, metals, acids, flammable solvents and source of

ignition.

In case of spill, do not touch the spilled material. Cover with wet earth and sand.

Eliminate all ignition sources.

Always use protective clothing with dust respirator and goggles while handling.

Hydrogen: It is a flammable, colorless, compressed gas packaged in cylinders at

high pressure. It poses an immediate fire and explosive hazard when concentrations

exceed 4%. It is much lighter than air and burns with an invisible flame.

It should be noted that, before suffocation could occur, the lower flammability of

hydrogen in air would exceed possibly causing both an oxygen-deficient and

explosive atmosphere. Exposure to moderate concentrations may cause dizziness,

headache, nausea and unconsciousness.

Cylinder storage locations should be well protected, well ventilated, dry, and

separated from combustible materials. Cylinders should never knowingly be allowed

to reach a temperature exceeding 52 0C. Cylinders of hydrogen should be separated



from oxygen cylinders or other oxidizers by minimum distance of 20 ft. Do not keep

any other cylinders in Hydrogen storage area.

Cylinders should be stored upright with valve protection cap in place and firmly

secured to prevent falling or being knocked over. Protect cylinders from physical

damage, do not drag, roll, slide or drop. Post ―No Smoking or Open flames‖ signs in

the storage areas. There should not be any sources of ignition.

All electrical equipment should be explosion proof in the storage and use areas.

Provide natural or explosion-proof ventilation adequate to ensure hydrogen does not

reach its lower explosive limit of 4% .Hydrogen is incompatible with oxidizing agents.

Sulfuric acid: Water Reaction

Reaction with water is negligible unless acid strength is above 70% then heat from

hydrolysis is extreme, may cause severe burns

Fire Hazard

It is highly reactive and capable of igniting finely-divided combustible materials on

contact. When heated, it emits highly toxic fumes. Avoid heat; water and organic

materials. Sulfuric acid is explosive or incompatible with an enormous array of

substances. It can undergo violent chemical change at elevated temperatures and

pressure. It may react violently with water.

Health Hazard:

Corrosive to all body tissues. Inhalation of vapor may cause serious lung damage.

Contact with eyes may result in total loss of vision. Skin contact may produce severe

necrosis.

Fatal amount for adult: between 1 teaspoonful and one-half ounce of the

concentrated chemical. Chronic exposure may cause tracheobronchitis, stomatitis,

conjunctivitis, and gastritis. Those with chronic respiratory, gastrointestinal, or

nervous diseases and any eye and skin diseases are at greater risk.

Protective Clothing:

Skin: Wear appropriate personal protective clothing to prevent skin contact.

Eyes: Wear appropriate eye protection to prevent eye contact.



Wash skin: The worker should immediately wash the skin when it becomes

contaminated.

Remove: Work clothing that becomes wet or significantly contaminated should be

removed and replaced. Provide: Eyewash fountains should be provided in areas

where there is any possibility that workers could be exposed to the substance; this is

irrespective of the recommendation involving the wearing of eye protection.

Facilities for quickly drenching the body should be provided within the immediate

work area for emergency use where there is a possibility of exposure.

It is intended that these facilities provide a sufficient quantity or flow of water to

quickly remove the substance from anybody areas likely to be exposed.

Hydrochloric acid:

Water Reaction

It is an aqueous solution. Dilution may generate heat. Fumes in air.

Fire Hazard

Special Hazards of Combustion Products: Toxic and irritating vapors are generated

when heated.

Health Hazard

Inhalation of fumes results in coughing and choking sensation, and irritation of nose

and lungs. Liquid causes burns.

Reactivity Profile

Hydrochloric Acid is an aqueous solution of hydrogen chloride, an acidic gas. Reacts

exothermically with organic bases (amines, amides) and inorganic bases (oxides and

hydroxides of metals).

Reacts exothermically with carbonates (including limestone and building materials

containing limestone) and hydrogen carbonates to generate carbon dioxide.

Reacts with sulfides, carbides, borides, and phosphates to generate toxic or

flammable gases.

Reacts with many metals (including aluminum, zinc, calcium, magnesium, iron, tin

and all of the alkali metals) to generate flammable hydrogen gas.



Protective Clothing:

Skin: If chemical is in solution, wear appropriate personal protective clothing to

prevent skin contact and to prevent skin from becoming frozen from contact with the

liquid or from contact with vessels containing the liquid.

Eyes: Wear appropriate eye protection to prevent eye contact with the liquid that

could result in burns or tissue damage from frostbite.

Wash skin: If the chemical is in solution, the worker should immediately wash the

skin when it becomes contaminated.

Remove: If chemical is in solution, work clothing that becomes wet or significantly

contaminated should be removed and replaced.

Provide: Eyewash fountains should be provided (when chemical is in solution) in

areas where there is any possibility that workers could be exposed to the substance;

this is irrespective of the recommendation involving the wearing of eye protection.

Facilities for quickly drenching the body should be provided (when chemical is in

solution) within the immediate work area for emergency use where there is a

possibility of exposure. It is intended that these facilities provide a sufficient quantity

or flow of water to quickly remove the substance from anybody areas likely to be

exposed.

Quick drench facilities and/or eyewash fountains should be provided within the

immediate work area for emergency use where there is any possibility of exposure to

liquids that are extremely cold or rapidly evaporating.

Thionyl chloride:

A colorless to yellow fuming liquid with a suffocating pungent odor. A lachrymator.

Highly corrosive and toxic.

Long-term inhalation of low concentrations or short-term inhalation of high

concentrations has adverse health effects.

Emits dense corrosive fumes in moist air. Violently reacts with water to liberate

hydrochloric acid and sulfur dioxide. Based on a scenario where the chemical is

spilled into an excess of water (at least 5 fold excess of water), half of the maximum

theoretical yield of Sulfur Dioxide gas will be created in 0.25 minutes.



Protective Clothing

Skin: Wear appropriate personal protective clothing to prevent skin contact.

Eyes: Wear appropriate eye protection to prevent eye contact.

Wash skin: The worker should immediately wash the skin when it becomes

contaminated.

Provide eyewash fountains in areas where there is any possibility that workers could

be exposed to the substance; this is irrespective of the recommendation involving

the wearing of eye protection

7.5. SAFE PRACTICES [HANDLING, STORAGE, TRANSPORTATION AND

UNLOADING OF CHEMICALS]

Liquid Raw materials will be transferred from the drums to the day tank situated at

the production block with the help of leak proof drum pumps / AODD pumps

/Vacuum. From day tank to process reactor unloading is by gravity.

7.5.1 Measures to Avoid Evaporation

All liquid chemicals/solvents stored in containers will be tightly closed.

Will Keep away from heat, sparks, and flame

Will Keep away from sources of ignition

Ammonia will be stored in well ventilated area away from combustibles,

oxidizable materials etc.

7.5.2 Safety Systems

Designated areas with proper indication & safety signs

Double earthling systems for all solvent storage tanks & process reactors

Flame arrestor to the vent of Solvent storage tanks

Flame proof transferring pumps for all flammable chemicals

Handling precautions/sop protocol

Pressure Gauges and temperature gauges on each reactor

Level indicators, Vent lines, earthing system on all solvent storage

tanks(Methanol, Toluene, MDC, Ethyl acetate, ,Acetone,THF)

Each solvent storage tank will be placed in dyke wall with Fire hydrant system

Flame proof lighting to solvent storage yard

Safety valve & Rupture disc on each process reactor.



Well ventilated warehouse with suitable fire extinguishers will be used for

storage of liquid chemicals/ Thionyl chloride/ HCl / H2SO4/Solid Chemicals.

7.5.3 TRANSPORTATION / UNLOADING

Highly inflammable chemicals will be transported by road. Therefore, adequate

safety precautions for transportation will be followed. During transportation of

hazardous chemicals, MSDS & TREM card will be provided to driver. As per Motor

Vehicle Rules, PESO rules and Factory Rules all safety precautions will be followed

during transportation of hazardous chemicals.

The following safety precautions are suggested during transportation of toxic,

inflammable and corrosive chemicals in tankers, while loading and unloading,

transportation and meeting the emergencies arising out of leakages and spillages of

hazardous materials:

The name of the chemical along with pictorial sign denoting the dangerous

goods should be marked on the vehicle and the packing material.

The name of the transporter, his address and telephone number should be

clearly written on the road tanker and on the vehicle.

Only trained drivers and cleaners should transport hazardous chemicals.

The Tanker / Vehicle should be checked for its fitness and safe condition

before loading.

During loading and unloading, the tanker/vehicle should be braked and

isolated against any movement, while loading/unloading, use safety

appliances.

Park the vehicle at designated place.

Stop the engine.

Check-up spark arrester.

Provide earthing to tanker securely.

Ensure that fireman is available near the place with proper equipment‗s.

Connect the piping properly

Before start unloading, check that, there should not be any leakage.

In case of leakage, immediately attend the leakages & rectify it.

After unloading is over, close the lid properly.

Vehicle to be started only after removal of all pipelines connected with tanker.



7.5.4 SPILL CONTROL

For all chemicals spill control procedures will be displayed. Spillage shall be

controlled as per concerned spill control procedure.

Like any spilled materials to contain, absorb spilled liquid by dry absorbent

clay or vermiculite.

Collect most of the contaminated absorbent with shovel for further

disposal/incineration.

If material spills directly on the ground, dig up and remove saturated soil for

disposal/incineration.

In case HCl/ H2SO4 spills on to the ground use dry absorbent clay/vermiculate

and neutralize with sodium carbonate

The plant is more vulnerable for solvent leakages, fire due to Raney nickel

exposure to dry condition.

7.5.5 EFFECT AND CONSEQUENCE ANALYSIS

In a plant handling hazardous chemicals, the main hazard due to storage &

handling of solvents, Thionyl chloride, Hydrogen, HCl/ H2SO4, Sodium

borohydride,

If Flammable chemicals are released into the atmosphere, they may cause

damage due to resulting fires or vapor clouds.

Toxic gas dispersion due to leakage of Thionyl chloride into atmosphere may

cause health problems to plant personnel and surrounding areas of the plant.

7.6 INVENTORY

Inventory analysis is commonly used in understanding the relative hazards

and short listing of release scenarios.

Inventory plays an important role in regard to the potential hazard.

Larger the inventory of a vessel or a system, larger the quantity of potential

release.

The potential vapor release [source strength] depends upon the quantity of

liquid release, the properties of the materials and the operating conditions

[pressure, temperature].



If all these influencing parameters are combined into a matrix and vapor

source strength estimated for each release case, a ranking should become a

credible exercise.

7.7 LOSS OF CONTAINMENT

Plant inventory can get discharged to environment due to Loss of

Containment.

Certain features of materials to be handled at the plant need to the clearly

understood to firstly list out all significant release cases and then to short list

release scenarios for a detailed examination.

Liquid release can be either instantaneous or continuous.

Failure of a vessel leading to an instantaneous outflow assumes the sudden

appearance of such a major crack that practically all of the contents above the

crack shall be released in a very short time.

The more likely event is the case of liquid release from a hole in a pipe

connected the vessel. The flow rate will depend on the size of the hole as well

as on the pressure, which was present, in front of the hole, prior to the

accident. Such pressure is basically dependent on the pressure in the vessel.

The vaporization of released liquid depends on the vapor pressure and

weather conditions.

In the study the largest potential hazard inventories have been considered for its

consequence Risk estimation how vulnerable the organization is to a specific icident

consequence.

There are a number of hazards that are present at the proposed project site that may

result in injury to people or a fatality in more serious cases. This study is only

concerned with ‗major hazards‘, which are as follows:

Pool fires

Hydrocarbon fires associated with tank failures;

Vapor cloud explosion;



Each of these hazards has been described below.

Jet Fire

Jet fires result from ignited releases of pressurized flammable gas or

Superheated/pressurized liquid. The momentum of the release carries the material

forward in a long plume entraining air to give a flammable mixture.

Jet fires only occur where any other flammable gas is being handled under pressure

or when handled in gas phase and the release are unobstructed.

Pool Fires

If a liquid release has time to form a pool and is then ignited before the pool

evaporates or drains away, then a pool fire results.

Because they are less well aerated, pool fires tend to have lower flame temperatures

and produce lower levels of thermal radiation than some other types of fire (such as

jet fires); however, this means that they will produce more smoke. Although a pool

fire can still lead to structural failure of items within the flame, this will take several

times longer than in a jet fire.

A burning liquid pool can spread along a horizontal surface or run down a vertical

surface to give a running fire. Due to the presence of kerbs, slopes, drains and other

obstacles; pool fire areas and directions can be unpredictable.

Vapour Cloud Explosion

The facility presently stores and also plans to store highly flammable Chemicals

Methanol, Acetone, Toluene, MDC, Ethyl acetate, THF, Raney Nickel, etc. for a

maximum credible loss scenario the release of such chemicals is likely to form a

vapor cloud. If the cloud encounters an ignition source, the parts of the cloud where

the concentration is within the flammable range will burn and may in some situations,

also create an explosive force (blast wave). The effects of an explosion, defined by

blast overpressure, can be significant.

In most VCEs the expanding flame front travels more slowly than the pressure

Wave; this type of explosion is called a deflagration and the maximum Overpressure

is determined by the expansion ratio of the burning gases. If the flame front travels

fast enough to coincide with the pressure wave then the explosion is called a

detonation and very severe overpressures can be produced. Detonation is most

likely to occur with more reactive gases such as hydrogen.



Toxic vapor release:

Toxic vapor release due to Thionyl chloride leakage and effected area with airborne

concentration.

7.8 Damage Criteria

In consequence analysis, use is made of a number of calculation models to estimate

the physical effects of an accident [spill of hazardous material] and to predict the

damage [lethality, injury, material destruction] of the effects. The calculations can

roughly be divided in three major groups.

Determination of the source strength parameters;

Determination of the consequential effects;

Determination of the damage or damage distances.

Table 7.3: Severity Categories and Criteria

Consequence Ranking Criteria Definition

Catastrophic 5 Multiple fatalities/permanent total disability

Major 4 Single fatality/permanent total disability

Moderate 3 Short term hospitalization & rehabilitation leading to recovery

Minor 2 Medical treatment injuries

Insignificant 1 First Aid treatment

Risk Evaluation

Based on ranking of likelihood and frequencies, each identified hazard has been

evaluated based on the likelihood of occurrence and the magnitude of

consequences. The significance of the risk is expressed as the product of likelihood

and the consequence of the risk event, expressed as follows:

Significance = Likelihood X Consequence

The below table illustrates all possible product results for the five likelihood and

consequence categories while the next table assigns risk significance criteria in three

regions that identify the limit of risk acceptability.

Depending on the position of the intersection of a column with a row in the risk

matrix, hazard prone activities have been classified as low, medium and high thereby

qualifying for a set of risk reduction / mitigation strategies.



Risk Matrix

Likelihood

Consequence Frequent Probable Unlikely Remote Improbable

5 4 3 2 1

Catastrophic 5 25 20 15 10 5

Major 4 20 16 12 8 4

Moderate 3 15 12 9 6 3

Minor 2 10 8 6 4 2

Insignificant 1 5 4 3 2 1

Risk Criteria and action Requirements

S. No. Risk Significance Criteria Definition & Action Requirements

1 High (16-25)

―Risk requires attention‖ – Project Management need to ensure that necessary mitigation are adopted to ensure that possible risk remains within acceptable limits.

2 Medium (10-15)

―Risk is tolerable‖ – Project Management to adopt necessary measures to prevent any change/modification of existing risk controls and ensure implementation of all practicable controls.

3 Low (5-9)

―Risk is acceptable‖ – Project related risks are managed by well established controls and routine processes/procedures. Implementation of additional controls can be considered.

4 Very Low (1-4)

―Risk is acceptable‖- All risks are managed by well established controls and routine processes/procedures. Additional risk controls need not to be considered.

The basic physical effect models consist of the following.

Source strength parameters

Calculation of the outflow of liquid, vapor out of a vessel or a pipe, in case of

rupture. Also two-phase outflow can be calculated.

Calculation, in case of liquid outflow, of the instantaneous flash evaporation

and of the dimensions of the remaining liquid pool.

Calculation of the evaporation rate, as a function of volatility of the material,

pool dimensions and wind velocity.

Source strength equals pump capacities, etc. is some cases.



Consequential effects

Dispersion of gaseous material in the atmosphere as a function of source

strength, relative density of the gas, weather conditions and topographical

situation of the surrounding area.

Intensity of heat radiation [in KW / m2] due to a pool fire, as a function of the

distance to the source.

Energy of vapor cloud explosions [in KW / m2], as a function of the distance to

the distance of the exploding cloud.

Concentration of gaseous material in the atmosphere, due to the dispersion of

evaporated chemical. The latter can be either explosive or toxic.

It may be obvious, that the types of models that must be used in a specific risk study

strongly depend upon the type of material involved:

Gas, vapor, liquid, solid

Inflammable, explosive, toxic products

Stored at high/low temperatures or pressure.

Selection of Damage Criteria

The damage criteria give the relation between extent of the physical effects

(exposure) and the percentage of the people that will be killed or injured due

to those effects

The knowledge about these relations depends strongly on the exposure. For

instance, much more is known about the damage caused by heat radiation,

than about the damage due to toxic exposure, and for these toxic effects, the

knowledge differs strongly between different materials.

In consequence analysis studies, in principle three types of exposure to hazardous

effects are distinguished:

Heat radiation from pool fire.

Explosion

Toxic effect from toxic materials or toxic combustion products.

Heat Radiation

The consequence caused by exposure to heat radiation is a function of:



The radiation energy onto the human body [KW / m2]

The exposure duration [sec]

The protection of the skin tissue [clothed or naked body]

7.9 DAMAGES TO HUMAN LIFE DUE TO HEAT RADIATION

Injuries to People —Definition of Burn Degrees

First Degree: A mild level of skin burn affecting the epidermis, with persistent

redness but no formation of blisters. More severe first - degree burns will produce

some pain, but no permanent damage. Flaking or scaling of the outer skin layer will

occur several days after exposure.

Second Degree: An intermediate level of skin burn characterized by the formation of

blisters. The blister depth may be shallow (epidermis), with only the surface layers of

the skin damaged, or more severe with nearly the full depth of the skin destroyed

(epidermis and dermis).

Third Degree: Deep burns characterized by the destruction of all skin layers and by

charring. The underlying tissue may also be damaged.

Table 7.4 Heat flux Intensity and exposure time-Damage criteria for people

Thermal Radiation Intensity (kW/m2)

Type of Damage

1.6 No harm for long exposures.

4 to 5 Pain for 20 seconds exposure; first degree burn

9.5 Second degree burn after 20 Seconds

10 to 15 Potentially lethal with in 1 minute.

25 Significant injury in 10 seconds; 100 % lethality in 1 minute.

35 to 37.5 1 % lethality in 10 seconds.

Since in practical situations, only the own employees will be exposed to heat

radiation in case of a fire, it is reasonable to assume the protection by clothing. It can

be assumed that people would be able to find a cover or a shield against thermal

radiation in 10 sec. time. Furthermore, 100% lethality may be assumed for all people

suffering from direct contact with flames, such as the pool fire, a flash fire or a jet

flame.

Explosion

In case of vapor cloud explosion, two physical effects may occur:



A flash fire over the whole length of the explosive gas cloud;

A blast wave, with typical peak overpressures circular around ignition source.

As explained above, 100% lethality is assumed for all people who are present within

the cloud proper.

The following damage criteria may be distinguished with respect to the peak

overpressures resulting from a blast wave:

Table 7.5: DAMAGE DUE TO OVERPRESSURES

PEAK OVERPRESSURE

DAMAGE TYPE

0.83 bar Total destruction

0.30 bar Heavy damage

0.10 bar Moderate damage

0.03 bar Significant damage

0.01 bar Minor damage

7.10 MAXIMUM CREDIBLE LOSS ACCIDENT SCENARIOS

A Maximum Credible Accident (MCA) can be characterized as the worst credible

accident. In other words: an accident in an activity, resulting in the maximum

consequence distance that is still believed to be possible. A MCA-analysis does not

include a quantification of the probability of occurrence of the accident. Another

aspect, in which the pessimistic approach of MCA studies appears, is the

atmospheric condition that is used for dispersion calculations. The Maximum

Credible Loss (MCL) scenarios have been developed for the Facility. The MCL

cases considered, attempt to include the worst ―Credible‖ incidents-what constitutes

a credible incident is always subjective. Nevertheless, guidelines have evolved over

the years and based on basic engineering judgment, the cases have been found to

be credible and modeling for assessing vulnerability zones is prepared accordingly.

The objective of the study is Emergency planning, hence only holistic & conservative

assumptions are used for obvious reasons. Hence, though the outcomes may look

pessimistic, the planning for emergency concept should be borne in mind whilst

interpreting the results.



In Consequence analysis, geographical location of the source of potential release

plays an important role. Consideration of a large number of scenarios in the same

geographical location serves little purpose if the dominant scenario has been

identified and duly considered.

The Consequence Analysis has been done for selected scenarios. The details of

software used for MCA analysis are described below.

A computer based version ALOHA is used to calculate toxic and explosive

effect of the accidental release of liquid chemicals within the plant area.

ALOHA models key hazards-toxicity, flammability, thermal radiation (Heat),

and over pressure (expansion blast force)-related to chemical releases that

result in toxic gas dispersion, fire and/or explosion

7.11. Risk analysis

Risk Analysis – Thionyl chloride/ Solvents (Methanol, IPA and Acetone)

The main hazard Toxic gas release associated with the storage and handling of

Thionyl chloride with respect to the proposed Unit.

Hazards associated with the storage and handlings of Flammable chemicals

(Solvents) are pool fire and VCE‘s resulting from the ignition of released material.

The hazards may be realized during tank overfilling and leaks/failures in the storage

tank and ancillary equipment such as transfer pumps, metering equipment, etc. all of

which can release significant quantities of flammable material or toxic material on

failure.

7.12 Risk Modeling Scenarios

In addition to overfill, the scenarios considered for liquid and gaseous

Chemical leaks and catastrophic failures. Factors that have been identified as having

an effect on the integrity of tanks are related to design, inspection, maintenance, and

corrosion.

From the liquid chemicals Thionyl chloride has been considered for the

consequences analysis considering its hazardous nature, Storage conditions and

threshold values.



From the Solvents – Methanol, Acetone, IPA have been considered for the

consequences analysis considering their hazardous nature, Storage conditions and

threshold values.

RISK & VULNERABLE AREAS

SITE DATA:

Location: SGR LABORATORIES, TELANGANA, INDIA

CHEMICAL DATA:

Chemical Name: ACETONE

CAS Number: 67-64-1

Molecular Weight: 58.08 g/mol

Ambient Boiling Point: 55.6° C

ATMOSPHERIC DATA:

Wind: 1 meters/second from N at 3 meters

Ground Roughness: open country

Air Temperature: 44.5° C

Relative Humidity: 65%

SOURCE STRENGTH:

Leak from hole in vertical cylindrical tank

Flammable chemical is burning as it escapes from tank

Tank Diameter: 2.5 meters

Tank Length: 5.2 meters

Tank Volume: 25.5 cubic meters

Tank contains liquid

Internal Temperature: 30° C

Chemical Mass in Tank: 16000 kilograms

Tank is 80% full

Circular Opening Diameter: 4 inches

Opening is 2 inches from tank bottom

Total Amount Burned: 15907 KGS



THREAT ZONE:

Threat Modeled: Thermal radiation from pool fire

Red : 17 yards --- (10.0 kW/(sq m) = potentially lethal within 60 sec)

Orange: 27 yards --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)

Yellow: 43 yards --- (2.0 kW/(sq m) = pain within 60 sec)

In case the Leakage of Acetone from storage tank got ignited, the vulnerable

areas, which are in radius of 15.5 meters within a minute, will get affected.

The Thermal radiation from pool fire of Acetone having value of 10 kw/sqm is

potentially lethal to the plant personnel from North of the plant with in the

radius of 15.5 meters .The plant personnel with in radius of 24.6 meters are

vulnerable for second degree burns within a minute.

The leakage of Acetone in the plant and its consequence considered as Major

and its likelihood is unlikely


=3*4

=12

As defined in Risk Criteria and action requirements

The risk significance is Medium.

―Risk is tolerable‖ –

Mitigation measure: It is Flammable liquid. Storage tank should be checked at

regular intervals for any corrosion, weak joints and tank bottom isolation valve for



its operating condition and earthing of the tank. Check regularly earth pit

resistance. At any point of time do not place any ignition source near by the tank.

In case of fire use fire hydrant system to extinguish the fire in order to minimize

the risk level and avoid fire spread to other areas of the plant. Inform plant head

for emergency preparedness. Put water curtain on adjacent tanks to avoid heat

radiation to contents of the tank.

Each tank will have dyke wall in all four sides and capacity of dyke wall will retain

entire contents of storage tank in case leakage of its contents.

Each tank is fitted with Flame arrestor.

The fabrication and installation of Storage tank will be as per the Petroleum rules -

2002.

Construction of tank will be as per IS 10987(1992).

The scale of fire fighting will be provided as per Oil Industry Safety Directorate

(OISD) Standard-117 and it will be approved by Chief controller of explosives.

For firefighting water storage tank will be provided and water will be sufficient for four

hours.

Adequate fire hydrants and fire extinguishers will be provided as per OISD-117

Standard.

Capacity of each fire hydrant will have water flow rate of 36m3 /hr at a pressure of 7

kg/cm2

Flash Point: -20 deg C

In view of low flash point continuously Acetone vapors will be generated from the

tank contents hence, to condense the vapors a heat exchanger will be fitted to the

vent .The condensing liquid will be put back to Storage tank

Explosion Limits, Lower: 2.6 vol % Upper: 12.8 vol %

To avoid formation of explosive limits Nitrogen positive pressure will be arranged in

the tank.

CHEMICAL DATA:

Chemical Name: METHANOL

CAS Number: 67-56-1


Ambient Boiling Point: 64° C



ATMOSPHERIC DATA:





SOURCE STRENGTH:









Tank is 80% full




THREAT ZONE:







In case the Leakage of Methanol from storage tank got ignited, the vulnerable

areas, which are in radius of 15.5 meters within a minute, will get affected.

The Thermal radiation from pool fire of Methanol having value of 10 kw/sqm is

potentially lethal to the plant personnel towards North side of the plant with in the

radius of 15.5 meters.

The plant personnel will be vulnerable for second degree burns within the radius

of 21.9 meters in a minute.

The fire due to leakage of Methanol in the plant and its consequence considered

as Major and its likelihood is unlikely


=3*4 =12




Mitigation measure: It is highly flammable liquid in presence of open flames and

spark. Storage tank should be checked at regular intervals for any corrosion,

weak joints and tank bottom isolation valve for its operating condition and

earthing of the tank. Check regularly earth pit resistance. At any point of time do

not place any ignition source near by the tank.



In case of fire use fire hydrant system and fire extinguisher -alcohol foam to

extinguish the fire in order to minimize the risk level and avoid fire spread to other

areas of the plant.

Inform plant head for emergency preparedness. Put water curtain on adjacent

tanks to avoid heat radiation to contents of the tank.





2002.





hours.


Standard.


kg/cm2

Flash Point: 12 deg C

In view of low flash point continuously Methanol vapors will be generated from the

tank contents hence, to condense the vapors a heat exchanger will be fitted to the

vent .The condensing liquid will be put back to Storage tank

Explosion Limits, Lower: 6 vol % Upper: 36.5 vol %


the tank.

CHEMICAL DATA:

Chemical Name: ISOPROPANOL

CAS Number: 67-63-0



ATMOSPHERIC DATA:







SOURCE STRENGTH:









Tank is 81% full




THREAT ZONE:







In case the Leakage of IPA from storage tank got ignited, the vulnerable areas,

which are in radius of 17.3 meters within a minute, will get affected.

The Thermal radiation from pool fire of IPA having value of 10 kw/sqm is

potentially lethal to the plant personnel towards south side of the plant with in

the radius of 17.3 meters .The plant personnel with in radius of 25.6 meters are

vulnerable for second degree burns within a minute.

The leakage & fire of IPA in the plant and its consequence considered as Major

and its likelihood is unlikely


=3*4 =12




Mitigation measure: It is flammable liquid in presence of open flames and spark.

Storage tank should be checked at regular intervals for any corrosion, weak joints

and tank bottom isolation valve for its operating condition and earthing of the

tank. Check regularly earth pit resistance. At any point of time do not place any

ignition source near by the tank.

In case of fire use fire hydrant system and fire extinguisher -alcohol foam to

extinguish the fire in order to minimize the risk level and avoid fire spread to other

areas of the plant. Inform plant head for emergency preparedness. Put water

curtain on adjacent tanks to avoid heat radiation to contents of the tank.





2002.





hours.


Standard.




kg/cm2

Flash Point: 18.3 deg C

In view of low flash point continuously IPA vapors will be generated from the tank

contents hence, to condense the vapors a heat exchanger will be fitted to the vent

.The condensing liquid will be put back to Storage tank

Explosion Limits, Lower: 2 vol % Upper: 12.7 vol %


the tank.

CHEMICAL DATA:

Chemical Name: THIONYL CHLORIDE

CAS Number: 7719-9-7



ATMOSPHERIC DATA:





SOURCE STRENGTH:

Direct Source: 100 kilograms

Total Amount Released: 100 KGS

THREAT ZONE:

Model Run: Heavy Gas

Red : 783 yards --- (14 ppm = AEGL-3 [60 min])

Orange: 1436 yards --- (2.4 ppm = AEGL-2 [60 min])



The leakage of Thionyl chloride liquid and its consequences are considered

as Minor and its likelihood is probable


=2*4 =8


The risk significance is low.

―Risk is Acceptable.‖ –

Mitigation measure: During unloading from Drum if unloading transfer pipe is not

fixed properly there may be sudden leakage of contents on to the ground. This

results in formation toxic area of vapor cloud of AEGL value 14 ppm up to a distance

of 715 mts in which people may experience life threatening health effects within one

hour.

AEGL value having more than 2.4 ppm up to a distance of 1313 mts in which people

may experience long lasting adverse health effects within one hour towards N side of

the plant.

During transfer of material it is advisable to use Air operated double diaphragm

pumps where spillages can be eliminated. While transferring the material the

responsible officer should be present.

7.13. OCCUPATIONAL HEALTH

Hazardous and toxic substances will be defined as those chemicals present in the

work place which are capable of causing harm.



For handling hazardous chemicals and to take care of employee‘s health, and

predictive maintenance looking to the nature of hazardous chemicals being

handled/processed. All the equipments in the plant areas shall be inspected /

tested by an outside agency.

The various safety equipments like breathing apparatus and critical

instrumentation will be provided on various equipments are inspected and tested

frequently to ensure their operability all the time. Besides, all the first aid, fire

fighting devices will be inspected, tested and maintained by a competent third

party and kept all the time in ready to use condition.

Health of all the employees in plant area will be monitored by outside physician.

If any abnormality is found necessary treatment is also being given time to time.

Necessary history cards, records will be maintained which is up-dated time to

time.

Common Hazards

Physical such as ventilation, poor illumination, noise, extreme temperature,

humidity and radiation.

Biological such as variety of pathogenic bacteria and parasites.

Chemical due to hazardous gases and dusts.

Ergonomic.

Industrial Hygiene Monitoring

Industrial hygiene monitoring is to be located and identify source of exposure in

the workplace so that they can be corrected and to quantify the exposure of

employees to chemicals in the air.

Air monitoring is conducted by industrial hygienists or other trained personnel.

Occupational Health Monitoring System

A. Air samples

Locations of samples – air samples are generally collected in one or three locations:

At the breathing zone of the worker [Personal sample]

In the general room air [Area sample]

At the operation which is generating the hazardous substance [Area sample]



Lengths of samples – Air samples are generally collected for two lengths of time.

Grab samples [instantaneous] measure conditions at one moment in time and

can be linked to a still photograph. They give only a picture of conditions at one

place at one instant in time.

Continuous Samples [range from twenty minutes to 8 – 10 Hours].These is

used to evaluate all day exposure by a series of continuous samples.

B. Other sampling methods

Bulk samples

Bulk samples will be collected from settled dust in the work place or from drums or

bags. Their purpose is to analyze and identify the substances present. For example,

bulk samples are used to analyze the percent of asbestos in insulation, dust &

Chemical Powder. Usually, a substance which is greater than one percent of bulk

sample is considered a concern.

Wipe Samples

Wipe samples will be used when skin absorption or ingestion is a suspected route of

exposure. The purpose is to show whether skin, respirators, clothing, lunch rooms,

lockers, etc. are contaminated.

It can show which surfaces are clean and which are contaminated. It can also show

if some surfaces are more contaminated than others.

7.13.1 Sampling Devices

The general principle of sampling is to collect an amount of a contaminant onto a

medium from a known quantity of air.

Air samples will be collected using small pumps to suck air from the workroom. The

pump is attached by tubing to a sampling device which contains the sampling

medium; for example a glass tube containing charcoal.

The sampling method will be used depends on the physical form of the substance:

DUSTS –The sampling device is a filter of plastic or paper in s holder:

VAPORS –The sampling device is a glass tube containing activated charcoal

as a medium.



GASES –The sampling device is a bubbler containing a fluid medium to

dissolved or react with the gas

The collected samples will be sent to a laboratory where the amount of the

substance on the sampling medium [filter, tube, etc.] is measured.

In some cases air monitoring will be conducted by using direct reading instrument

such as a monitoring for carbon monoxide these instruments can measure the

amount of a contaminant in the air immediately without being sent to a laboratory.

PELs [Permissible Exposure Limits] – these are legal‘s limits which have been

established by OSHA.

Recommended PELs – also reference to as RELs [Recommended Exposure

Limits] often these values are based on more recent scientific information than

the legal PELs enforced by OSHA.

TLVs [Threshold Limit Values] – These are exposure limits put out by a

nongovernmental group, the ACGIH [American Conference of Governmental

Industrial Hygienists]. Many of these were adopted as legal requirements.

Revised TLVs are often based on the most recent and accurate scientific

information.

Permissible Exposure Limits by OSHA [Occupational Safety and Health

Administration] when it started back in 1970.

IDLH [Immediate Dangerous to Life or Health] limits are prescribed by NIOSH

[National Institute of Occupational Safety and Health]

PAC [Protective action criteria] for Hazardous chemicals prescribed by

Emergency management issues special interest group, UNITED STATES.

AEGL [Acute exposure guideline levels] values given by U.S. Environmental

protection agency.



7.14 CHEMICALS EXPOSURE LIMITS

TABLE: 7 .6 CHEMICAL EXPOSURE LIMITS

S. No Chemical name ACGIH

[TLV ] ppm OSHA

[ PEL ] ppm

1 Methanol 200 200

2 Toluene 50 200

3 IPA 200 400

3 Acetone 500 1000

4 Ethyl acetate 400 400

5 MDC 50 500

6 Cyclohexane 300 300

7 Thionyl chloride 1 1

8 n-Hexane 50 50

Notes:

All the above Values are in ppm

PPE Means Personal Protective Equipment like Helmets, Safety Google,

Breathing apparatus, Nose Masks, Gloves, Gum Shoes etc.,

EMP for the Occupational Safety & Health Hazards: Chemicals exposure can be

kept within permissible exposure level (PEL) / Threshold Limit value (TLV) so as to

protect health of workers.

1. It is proposed to formulate and implement an EMP for Occupational Safety and

Health with following aim:

To keep air-borne concentration of toxic and hazardous chemicals below PEL

and TLV.

Protect general health of workers likely to be exposed to such chemicals

Providing training, guidelines, resources and facilities to concerned

department for occupational health hazards

Permanent changes to workplace procedures or work location to be done if it

is found necessary on the basis of findings from workplace Monitoring Plan.

2. Proposed EMP will be incorporated in Standard Operating Procedure also

3. The proposed EMP will also include measure to keep air-borne concentration of

toxic and hazardous chemicals below its PEL and TLV, like

Leak Surveys



Separate storage for toxic chemicals

Exhaust Ventilation

Proper illumination

Close processes to avoid spills and exposures

Atomization of process operations to hazards of manual handling of chemicals

Supply of proper PPEs like Air mask, Breathing canisters, Decontamination

procedure for empty drums and carboys.

Regular maintenance program for pumps, equipment, instruments handling

toxic and corrosive chemicals

Display of warning boards

Training to persons handling toxic and corrosive chemicals.

.4. Workplace Monitoring Plan

It is proposed that a Workplace Monitoring Plan to be prepared &

implemented accordingly.

Each workplace must be evaluated to identify potential hazards from toxic

substances or harmful physical agents. Air-borne concentration of toxic

chemicals will be measured and record will be kept.

The current state-of-the-art exposure measurement model is as follows: For

purposes of measuring worker exposure across a single shift it is sufficient to

place a reasonably accurate exposure measuring device near the worker‘s

area, within the worker‘s breathing zone, and have it operate for nearly the full

shift. Client has been proposed to study the exposure data when the plant is

operative.

5. Health Evaluation of Workers

It is proposed that management will devise a plan to check and evaluate the

exposure specific health status evaluation of workers.

Workers will be checked for physical fitness with special reference to the

possible health hazards likely to be present, where he/she is being expected

to work before being employed for that purpose. Basic examinations like

1. Liver Function tests

2. Chest X-ray

3. Audiometry



4. Spirometry Vision testing (Far & Near vision, color vision and any other

ocular defect)

5. ECG, etc. will be carried out.

However, the parameters and frequency of such examination will be decided in

consultation with Factory Medical Officer.

While in work, all the workers will be periodically examined for the health with

specific reference to the hazards which they are likely to be exposed to during

work. Health evaluation will be carried out considering the bodily functions

likely to be affected during work. The parameters and frequency of such

examination will be decided in consultation with Factory Medical Officer. Plan

of monthly and yearly report of the health status of workers with special

reference to Occupational Health and Safety, will be maintained.

7.15. TREATMENT OF WORKERS AFFECTED BY ACCIDENTAL SPILLAGE OF

CHEMICALS

[Interim First Aid for General Injuries & Wounds]

Interim First Aid is essential in many injuries while injured waits for trained personnel

to arrive.

BLEEDING

Apply direct pressure on the wound with a clean dressing.

If bleeding continues and you do not suspect a fracture, elevate the wound

above the victim‘s heart and continue to apply direct pressure.

If bleeding continues, apply pressure at a pressure point.

Maintain body temperature.

Do not use a tourniquet unless this is a serious amputation.

BREATHING PROBLEMS

Move victim to fresh air if smoke or dangerous gases are present.

Otherwise, do not move victim.

If victim loses consciousness, call doctor

Never enter into a room with toxic gases released -call without protection



UNCONSCIOUS VICTIM

Move victim to fresh air if smoke or dangerous gases exist.

Begin rescue breathing- is First Aid trained ahead of time

Never enter into a room where toxic gases released

CHEMICAL BURNS

Have victim remain under a safety shower or flush skin with an available

water source for 15-30 minutes.

Remove all contaminated clothing and jewellery.

Cover burns with dry, loose dressings.

Wash all clothing thoroughly before wearing it again.

ACID BURNS

In case of acid burn, the operators with all possible speed gets under a safety

shower and use the full flow of water. A small amount of water will incase

severity of the burn Water should be used until all traces of acid have been

washed from the burn. Alkaline solutions are not needed; if used at all they

will use only after all acid has been washed from the burn, it may to treat in

the same manner as a heat burn.

CHEMICAL INGESTIONS

Never enter into a room where toxic gases released, without protection

Do not give victim any food or liquids without specific advice from physician.

EYE INJURIES FROM CHEMICALS

Get victim to a safety shower or eye wash immediately.

Never enter into a room where toxic gases released

Flush eye for 15-30 minutes with both lids held open. Keep the injured eye

lower than the uninjured eye.

Keep the eyelids open hold fingers at top and bottom of the eyeball. Wrap a

bandage loosely around both eyes.

SAFE OPERATING PROCEDURES

Safe operating procedures will be available for all materials, operations and

equipment.



The workers will be informed of consequences of failure to observe the safe

operating procedures.

Safe operating procedures will be formulated and updated, specific to process

& equipment and distributed to concerned plant personnel.

Safety procedures will be prepared and displayed meticulously in Telugu and

English languages.

FIRE PROTECTION

Well-designed pressured hydrant system comprising with jockey pump,

electrical & diesel pumps, hydrant, monitor etc. Will be installed at the plant.

The fire fighting system and equipment will be tested and maintained as per

OISD-117 standard.

Heat and smoke detectors will be provided at the plant and warehouse

(solvent storage area) and calibrated.

STATIC ELECTRICITY

All equipment and Storage tanks / Containers of flammable chemicals are will

be bounded and earthed properly.

Electrical pits will be maintained clean and covered.

Electrical continuity for earthing circuits shall be maintained.

Periodic inspections shall be done for earth pits and record will be maintained.

7.16 COMMUNICATION SYSTEM

Communication facilities will be checked periodically for its proper functioning.

7.17 SAFETY INSPECTIONS

The system will be initiated for checklist based routine safety inspection and internal

audit of the plant. Safety inspection team will be formed from various disciplines and

departments.

7.18 PREDICTIVE AND PREVENTIVE MAINTENANCE

Predictive and preventive maintenance schedule will be followed in religious manner.



ELECTRICAL SAFETY

Insulation pad at HT panels will be replaced at regular interval.

Housekeeping in MCC room will be kept proper for safe working conditions.

COLOUR CODING SYSTEM

Colour coding for piping and utility lines are will be followed in accordance with IS:

2379:1990.

DISASTER MANAGEMENT PLAN

ONSITE EMERGENCY PLAN

OFFSITE EMERGENCY PLAN

7.19. ONSITE EMERGENCY PLAN

The details of Onsite emergency plan system are discussed in the following sections

DEFINING THE NATURE / LEVEL OF EMERGENCY

The levels of emergency can be classified in three categories

LEVEL-1

The leakage or emergency which is confinable the plant, premises. It may be due to-

Small fire in the plant

Low toxic gas release for short duration.

Collapsing of equipment that do not affect outside premises.

LEVEL-2

The emergency which is confinable within the factory premises. It may arise due to

Major fire inside the factory premises.

Medium scale explosion confined to the factory premises.

Heavy toxic/flammable gas leakage for short duration.

LEVEL-3

The emergency which is not confinable within the factory premises and general

public in the vicinity likely to be affected. It may arise due to

Explosion of high magnitude affecting the adjacent area

Heavy/profuse leakage of toxic/flammable gases for a long duration.



7.20 STRUCTURE OF EMERGENCY MANAGEMENT SYSTEM

The company will develop an emergency management team. The management

structure includes the following personnel

Site main Controllers

Incident Controllers and Deputy Incident Controllers

Key Personnel‘s

Essential Workers

The other elements of Disaster management plan are

Assembly points

Emergency control center

Fire control center

Medical arrangements

Other arrangements

7.21 EMERGENCY MANAGEMENT SYSTEM – ROLES & RESPONSIBILITIES

Roles and responsibilities of the responsible persons are described.

7.21.1 SITE MAIN CONTROLLER [SMC]

PLANT HEAD will be the site main controller. In absence of PLANT HEAD, EHS

HEAD will act as a SMC.

His task will be to co-ordinate all internal and external activities from the emergency

control centre at main security gate from where all operations will be directed. He

shall:

Immediately on being informed of the emergency and its location, will arrive

at the scene and handle the situation.

Relieve the incident controller from responsible of the main controller

Co-ordinate to avail services from external agencies like fire brigade,

hospitals etc. is called for, following the declaration of major emergency. If

necessary, major installations in the vicinity may also be informed of the

situation.

Exercise direct operational control of the unaffected section of the plant.



In consultation with the advisory team, expedite the shutting down of

loading/unloading operations of tankers and if necessary, instruct the

supervisor/security/personnel to evacuate tankers.

Ensure that all employees are evacuated from the affected area and the

casualties, if any, are given necessary medical attention. Instruct P&A

Assistant/security for rushing casualties to hospitals if required.

Liaise with fire and police officials, pollution control board officials and other

statutory bodies and advise them of all possible consequence effects

outside the premises.

Arrange for relief of personnel when emergency is prolonged

Issue authorized statement or press release to the news –media

Ensure preservation of evidence for enquiries to be conducted by statutory

authorities.

Authorize the sounding of “All Clear” and “Evacuation Siren”

Arrange for obtaining the head-count of all personnel within the premises

and cross-checking with the data from records available for no. of persons

within the premise.

7.22 INCIDENT CONTROLLER/ DEPUTY INCIDENT CONTROLLER

Role of Incident Controller [Plant Manager/ Shift in Charge]: He is the shift supervisor

of the plant. Assume the role of the incident controller and take charge of the

situation. Keep the SMC informed of the situation from time to time.

1. Proceed to the scene of emergency and assess the situation

2. Direct all operation within the affected area with the following priorities

Safety of personnel

Minimize damage to property and loss of material

Arrange for rescue of trapped workers and those in a state of shock

Get all non-essential persons safely evacuated after stopping all the

engineering/hot jobs.

Set up a communication system with the main control center at the main

security gate through telephone or messenger system.

Pending arrival of the main controller, direct the shutting down and

evacuation of the site



Report all developments to the main controller

Preserve all evidence for use in the subsequent enquiry.

Intimate to the Emergency Control Center (Main Security Gate) the head

count of plant.

7.23 KEY PERSONNEL’S

Key Personnel are required to provide and to implement the decisions made

by the SMC in the light of information received on the developing situation at

the time of emergency.

As necessary, they will decide the actions needed to shut down plants,

evacuate personnel, carryout emergency engineering work, arrange for

supplies of equipment, utilities, carryout environment monitoring, provide

catering facilities, liaise with police, fire brigade and other local authorities,

relative of casualties, hospital, press & neighboring industries

Action at assembly points, outside shelters and mutual aid center under the

direction of the SMC.

All the key personnel and other called in so to assist shall report to the ECC.

They shall be available at any time on duty or on call or on holiday.

7.24 ESSENTIAL WORKERS

A task force of essential trained workers [Expert‘s team] is available to get the work

done by the Incident controller and the SMC. Such work will include:

Fire fighting and spill control till a FIRE BRIGADE takes the charge

To help FIRE BRIGADE and MUTUAL AID teams, if it is so required

Shutting down plant and making it safe

Emergency engineering work e.g. isolating equipments, material process,

providing temporary by pass lines, safe transfer of materials, urgent repairing

or replacement, electrical work, etc

Provision of emergency power, water, lighting, instruments, equipments,

materials, etc

Movement of equipment, special vehicle and transport to or from the scene of

the accident.

Search, evacuation, rescue and welfare.

The injured is given First Aid.



Moving tankers or other vehicles from area of risk.

Carrying out atmospheric test and pollution control.

Manning of assembly points to record the arrival of evacuated personnel.

Manning for outside shelters and welfare of evacuated persons there.

Assistance at causalities reception areas to record details of causalities.

Assistance at communication centers to handle outgoing and incoming calls

and to act as messengers if necessary.

Manning of works entrances in liaison with the police to direct emergency

vehicles entering the work. To control traffic leaving the works and to turn

away or make alternative safe arrangements for visitors for visitors,

contractors and other traffic arriving at the works.

Inform neighboring factories and the public as directed by the Site Main

Controller.

Any special help required.

7.25 OTHER ELEMENTS OF DMP

There are some other elements of DMP which are described as follows:

7.26.1 ASSEMBLY POINT

Assembly points are those locations where the persons who are not connected with

emergency operations can await either for further instructions or for rescue transport

and rehabilitation. Presently outside the plant area is considered as such assembly

points, taking into consideration of the size of the plant facilities. As the location of

security gate is far off the Assembly Point is not vulnerable for emergencies.

The affected & vulnerable plants, all non-essential workers [who are not

assigned any emergency duty] will be evacuated from the area & they shall

report to specified Assembly point.

Assembly Point shall be located at a safe place, well away from area of risk

and least affected by the down wind direction.

To ensure that workers do not have to approach the affected area to reach

the Assembly point proper location and numbers have been marked at

Assembly point.



Each Assembly Point is manned by a nominated person to record the names

and dept.

At each Assembly point duties of in - charge shall be displayed in brief.

Before reaching an Assembly point or subsequently, if it is required to pass

through an affected area or due to presence of toxic substances, suitable

PPE‘s including respirators, helmet etc., are issued & made available with

workers.

7.26.2 EMERGENCY CONTROL CENTER

The Emergency Control Center is the place or room from where the operations to

handle the emergency are directed and coordinated. Main Control Room has been

earmarked / identified as the Emergency Control Room. Fire Control Room shall be

earmarked / identified as the alternative Emergency Control Room to be operated in

case of unfavorable wind direction. Adequate Telecommunication System is

available in the Emergency Control Room.

The ECC center has been equipped with the following facilities.

1. Internal and external telephone including STD facility

2. Telephone directory

3. Factory layout plan

4. Map of the area

5. Employee blood group and their address

6. Messengers / Runners for sending messages

7. Adequate numbers of PPE‘s

8. Telephone nos. of mutual aid centers, Statutory authorities & Hospitals

7.26.3 FIRE SERVICES

Fire Fighting, Gas leak Control and Rescue operation

A] Role of Manager [Fire and Safety/shift in-charge]

Manager- Fire and Safety/ Shift In-charge will be the only person to direct

the fire fighting and emergency operation.

Keep the constant touch with the chief emergency controller.

Direct the crew members to the scene of emergency and arrange

replenishment of man power/equipment/extinguishing media etc.



B] Fire and Safety officer

On being notified about the location of fire/gas leakage immediately

proceed to the scene of incident with fire tender and crew.

Position the fire tender in upwind direction.

Decide his line of action in consultation with incident controller and take

appropriate measures to handle the emergency.

Assessing the severity of the incident immediately report to emergency

controller about the gravity of the situation.

He will assess the extra requirement required if any from the neighboring industry.

C] Fire Crew Members

On hearing fire alarm, emergency siren they shall immediately report to

control room and proceed to the scene of emergency and work under the

direction of shift fire & safety officer.

The personal availability at the scene of incident to be made optimize.

D] Emergency Squad Members

On hearing Emergency Siren ,they shall immediately report to site main

controller, safety in charge or incident controller

They shall combat the emergency situation as per the direction of site main

controller, Safety In- charge or Incident controller

They shall help for safe evacuation

7.26.4 MEDICAL SERVICES

A] Role of Chief Medical Officer/Medical Officer

He will contact immediately to chief emergency controller

He will render necessary treatment as first aid center and hospital.

He will arrange for hospitalization and treatment at outside hospitals if

required.

He will mobilize extra medical assistance from outside if necessary.

He will make arrangement for treating public if necessary.

B] Role of other Medical staff

As directed by medical officers.



7.26.5 SECURITY SERVICES

Role of H.O.D. (Security) / Security Officers

Receive message from the observer

Initiate the emergency siren to declare the emergency

Announce on the public address system

Arrange to close all the gates and stop traffic

Keep vehicle/ambulance ready and keep track of casualty sent to hospital

during off hours

Ensure that unauthorized persons/vehicles do not enter the premises

Organize the positioning and transport of vehicles near the main gate

Depute security guard for controlling traffic at the scene of emergency

Call up for additional help from the outside agency like fire brigade,

hospitals during off hours.

Role of Security Guard

On hearing emergency siren contact security officer and work under his

directions

7.26.6 MUTUAL AID

In emergency situations, resources over and above those available at the works may

be needed. Emergency Coordinator would be contacting neighboring factories for

help. A survey of industries who can come to help and also the help, they can extend

is done as mentioned below.

The help would be in the form of technical manpower, medical aid,

transport for rescue and Rehabilitation, fire fighting, additional special

protective wear or any other help as the case may be.

Manager – Fire & Safety who is Emergency Coordinator is assigned with

this responsibility and he would maintain liaison during non-emergency

period and ensure co-operation

Similarly, the help required from civil administration, in respect of medical

aid, transport, law and order, rehabilitation etc. are identified and liaison is

established with Mandal Revenue Officer and Police Officials.



7.27 EMERGENCY RESPONSE

Concept of operations deals with the possible steps associated with an emergency

response assuming the most severe emergency scenario. This includes:

Accident initiation and rising of alarm

Accident evaluation and emergency declaration

Off site and external agency notification

Implementation of onsite response actions

Implementation of protective actions and evacuations

Co-ordination of response action with external agencies

Management of emergency resources

Recovery and facilitate re-entry procedures

7.28 EMERGENCY CAPABILITIES

The primary emergency response facilities comprise with emergency control center

upon declaration of emergency, the main security gate office will become the

emergency control center [ECC]. The ECC is located in a low /minimal risk zone of

the plant.

7.29 EMERGENCY HANDLING PROCEDURES

Action plan

On hearing emergency declaration siren and announcement on public

address system, all key persons will rush to their nominated location and

start actions.

The main controller will continuously assess the situation by taking

feedback from the incident controller. He will consult the advisory team

members to get essential information if required but if does not required to

take help from advisory team; he can assign other jobs to advisory team.

Once the emergency is brought under control, Main Controller will inform to

security to give “ALL CLEAR” siren and announce on Public Address

System about termination of emergency.

In the case the emergency assumes off site dimensions and cannot be controlled,

then if the chief controller with his advisory team decides to evacuate the plant, he

will instruct the security to sound ―EVACUATION SIREN”



Procedure in case emergency tends to have off site implications

As per the sire plan and wind direction at the time of emergency, the likely

affected area will be identified and population within will estimated.

The police will be informed so that in-coming traffic on highway can be

controlled from both the ends. The police force will be helpful in

evacuation of villages, factories or other public places in the vicinity

The fire brigade will be informed and ambulance will be called and kept

ready to meet any eventuality.

Neighboring factories will be communicated for sending help.

Statutory authorities such as factory inspector, district collector and others

concerned to be intimated.

Procedure for salvage operations

The salvage operation will be carried out under the guidance of the main

controller, his advisory team and incident controller.

They will conduct accident investigation; assess the damages-the clock by security

supervisors.

During emergency, the main controller and his advisory-team will confirm:

Layout of facility, equipment and storages, displayed on table and wall

Availability and location of personal protective equipment

Self-contained breathing apparatus sets and the spare cylinders

External telephone with direct dialing and STD facilities/Mobile phone

Internal telephone

List of important internal and external telephone numbers displayed on

table and wall.

Transport facility

Extra copies of plant layout for marking during emergency

General stationary like paper, pencil etc.

Nominal roll and address of all employees with contract telephone no‘s

and blood group

List of first aiders and emergency squad members

Details of all contractors and their employees.

Details of meteorological information during different seasons such as

wind speed, direction, temperature, humidity etc.



The location of ECC, Assembly point, availability of first aid boxes, fire extinguishers,

PPE should be marked onsite.

7.30 MITIGATION OF ENVIRONMENTAL IMPACT DURING FIRE EMERGENCY

In case of fire, prevent contact of fire with flammable material or prevent

of fire by other means

Use water or suitable fire extinguisher to extinguish fire

Contain the contaminated water or any other liquid to prevent it going to

soil or drain and divert it to ETP storage tank. If required treat it before

sending to ETP tank.

Any solid waste generated should be collected, stored and send to TSDF

site.

During fire emergency use necessary PPE.

Bottom valve failure: mitigation of environment impact during failure of

between valves or tank failure.

In case of material coming out of the bottom valve shall be contained

inside the dyke wall and will be transferred to HDPE plastic drum by help

of pump/piping.

In case of acid spillage after pumping shall be neutralized and waste shall

be cleaned with help of water and send the water to ETP.

The failed bottom valve shall be replaced or repaired and restart. After

tank is empty valve will be repaired, or replaced. In case of leakage form

tank body tank will be repaired.

Preventions of failure: preventive maintenance of bottom value shall be

carried out as per schedule. To prevent any leakage from tank body,

thickness checking shall be same as per schedule.

In case of bottom value failure or heavy leakages from tank body material

in the tank shall be transferred to the HDPE drums, by running the pump.

Preventions of failure: preventive maintenance of bottom valve shall be

carried out as per schedule. To prevent any leakage from tank body,

thickness checking shall be same as per schedule.

In case of any material leaching the soil it shall be neutralized and

washed with water.



7.30.1 RAISING THE ALARM

Emergency alarm shall be raised in the event of an emergency.

Any person noticing an unusual occurrence, fire, toxic or corrosive

substance leakage etc. shall inform the concerned department/section

head/shift in charge immediately and try to control/contain the incident.

Departmental head/shift in charge will immediately go to the site of

incident, assess the situation and initiate the action to ―blow the

emergency Alarm‖ by telephoning the main gate to security officer/Asst,

security officer/Security supervisor.

In case of telephone failure a messenger will be sent running to main gate

to inform.

Details of siren are given below

Siren codes

Declaration of emergency:- A long short wailing siren for one minute will

mean that there is an emergency within the premises.

All clear siren: - A long siren for one minute will mean that the emergency

declared is under control, i.e. all clear. This siren code will mean All clear,

normal condition.

Evacuation siren: - A long short wailing siren for 3 [three] minutes, will

mean that emergency declared cannot be controlled. Hence all persons in

the premises will evacuate as per the plan.

7.31 DECLARING MAJOR EMERGENCY

Major emergency may be declared after sufficient thought because it activates many

agencies and the nominated persons to declare major emergencies.

7.32 TRANSPORT AND EVACUATION ARRANGEMENTS

Arrangements shall be made for the transport and evacuation of persons in

case of any emergency situation arises in the factory.

Those employees who have own vehicles will make arrangements to shift the

injured.



7.33 PLANT OPERATIONS

1. Role of HOD

He will take plant related decisions, which will facilitate the fire fighting

operation.

2. Plant Employees

They shall:

On heaving the siren, report to plant supervisor

Do as directed by plant supervisor

Stop all hot works

Remove unwanted persons from the affected area to the ―Assembly Point

―near main security gate viz visitors, guests

Stop all non-essential operations

3. Non-plant Employees

On hearing the siren, shall stop their work assemble at ―Assembly Point‖ near main

security gate along with guests and visitors.

7.34 TELEPHONE MESSAGES

Telephone operator has to pay vital role in case of emergency. After hearing the

siren/ hooter, he/ she should inform to all key personnel immediately on phone. He/

she should receiving be very sharp, precise, attentive and quick in & noticing the

message.

7.35 MOCK DRILL

In spite of detailed training, it may be necessary to try out whether, the OSEP works

out and will there be any difficulties in execution of such plan. In order to evaluate

the plan and its effectives of meeting the objective of the OSEP, occasional mock

drills are contemplated. After a few pre- informed mock drills, few un-informed mock

drills would be taken. All this is to familiarize the employees with the concept and

procedures and to see their response. These scheduled and unscheduled mock

drills would be conducted during shift change, public holidays, in night shifts etc, to

improve preparedness. Emergency Coordinator [EHS] is responsible for organizing

planned and unplanned mock drills.

Two types of Mock drills are in practice. They are



1. Announced-Once in 3 months

2. Unannounced –Once in 6 months.

Mock drill observation

Mock drill observation team is constituted and they note down the action of various

coordinators in chronological order. The time of arrival of each coordinator and their

duties are detailed in a note. Immediately after mock drill, the advisory team and

emergency coordinators meet and review the mock drill records in chronological

order and take note of corrective action. The record of this meeting note is circulated

for compliance of concerned.

Role of Mock drill observers

Note readings of plant instruments

Meteorological conditions

Time of emergency declaration and time when the personnel responded /

reported

Ambulance reported and time when additional vehicles reported

Collect information description of the event, estimated quantity of the gas

release, fire, contamination and effected levels at various locations, injuries

and equipment damage.

7.36 OFFSITE EMERGENCY PLAN

―If the accident is such that its affects inside the factory are uncontrollable and it

may spread outside the factory premise, it is called as “OFFSITE EMERGENCY”



FLOWCHART FOR OFFSITE EMERGENCY PLAN

The Offsite emergency plan is made based on events, which could affect people and

Environment outside the premises. The off site plan is largely a matter of ensuring

the co-ordination of proposed services and their readiness as far as possible, for the

specific hazards and problems, which may arise in as incident. Briefly two main

purposes of the plan are as under:

To provide the local district authorities, police, fire brigade, doctors etc. the basic

Information of risk and environmental impact assessment and to appraise them of

the consequences and the protection / prevention measures and control plans and to

seek their help to communicate with the public in case of major emergency.

To assist the district authorities in preparing the Offsite emergency plan of the

district or particular area. We will make our key personnel and others fully aware

about this off-site emergency plan. The function of the offsite plans are as under:

Structure of the offsite emergency plan includes the following:-

Organizational set up-Incident controller /Site main controller, Key personnel,

etc

Communication facilities - List of important telephones



Specialized emergency equipment - Firefighting equipment

Specialized Knowledge - Trained people

Voluntary Organization - Details of organization

Chemical information - MSDS of hazardous substances

Meteorological information - Weather condition such as Wind velocity, Wind

Speed, Humidity, Temperature etc

Humanitarian arrangement - Transport, First aid and Ambulance

7.37 ROLE OF THE FACTORY MANAGEMENT

The Onsite and Offsite plans are come together so that the emergency services are

call upon at the appropriate time and are provided with accurate information and a

correct assessment of situation.

7.37.1 ROLE OF LOCAL AUTHORITY

Generally the duty to prepare the off-site plan lies with the local authority. They may

have appointed an Emergency Planning Officer (EPO) to prepare whole range of

different emergency within the local authority area.

7.37.2 ROLE OF FIRE AUTHORITY

The control of a fire is normally the responsibility of the senior fire brigade officer who

would take over the handling of fire from the Incident Controller on arrival at the site.

7.37.3 ROLE OF POLICE

The overall control of an emergency is normally assumed by the police with a senior

officer designated as emergency coordinating officer. Formal duties of the police

during emergency include protection of life and property and controlling traffic

movements.

7.37.4 ROLE OF HEALTH AUTHORITIES

Health authorities, including doctors, surgeons, hospitals, ambulances etc. have a

vital role to play following a major accident and they should form an integral part of

the emergency plan. Major off site incidents are likely to require medical equipments

and facilities in addition to those available locally.



7.37.5 ROLE OF THE “MUTUAL AID” AGENCIES

Some types of mutual aids are available from the neighboring factories, as per need,

as a part of the onsite and Offsite emergency plan.

7.37.6 ROLE OF THE FACTORY INSPECTORATE

In the event of an accident, the factory inspector will assist the District Emergency

Authority for information and help in getting mutual aid from neighboring factories.

Unit maintains the records of details of emergency occur, corrective preventive

measures taken and in future the same practice will be continued. Unit will be

displayed the details like list of assembly points, name of the persons involve in the

safety team like Site Controller, Incident controller etc.

PROJECT BENEFITS

CHAPTER -VIII


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter - VIII Page 304

CHAPTER – VIII

PROJECT BENEFITS

The proposed project will become beneficial to the surrounding area or community in

terms of employment, social development and other benefits as described hereunder;

8.1 EMPLOYMENT POTENTIAL

The proposed project has employment potential for skilled (50 persons), semi-skilled

(10 persons) and unskilled (40 persons). The preference will be given to local

population for employment; this will increase the employment opportunity in the

surrounding area. Indirect employment is also bound to be generated to provide day-to-

day needs and services to the work force and industrial activity. This will also increase

the demand for essential daily utilities in the local market. The employed people will be

benefited financially.

8.2 CORPORATE SOCIAL RESPONSIBILITY (CSR) & CORPORATE

ENVIRONMENT RESPONSIBILITY (CER)

SGR Laboratories Pvt. Ltd. not only carries out business but also understands

obligations towards the society. Unit will employ people from the nearby villages for the

proposed project. The wages paid to direct and indirect workforce in the proposed

project will fulfill their monetary requirements, which in turn leads to socio economic

development in the surrounding villages. The Project proponent is well aware of the

obligations towards the society and to fulfill the social obligations Unit will also try to

generate maximum indirect employment in the nearby villages by appointing local

contractors during construction phase as well as during operation phase. Unit will be

contributing reasonably as part of their CSR & CER activities. Unit will spend about

2.5% for CSR & 2% for CER activities like potable water supply & educational aid and

conduct medical camps & Self Help Skill Training to the nearby villages. CSR activities

identified and planned at present are described below Table.



CSR & CER BUDGET FROM SGR LABORATORIES PVT. LTD. Project Location : SGR Laboratories Pvt. Ltd.

CSR Plan Period : Five Years from the date of commercial production.

Project cost : Rs. 12 Crores

Corporate Social Responsibility Budget : Rs. 30 Lakhs [2.5% of the Project cost] for 5 Years

Corporate Environment Responsibility Budget : Rs. 24 Lakhs [2% of the Project cost]

S. No CSR & CER

Activity 1st

Year 2nd

Year 3rd

Year 4th

Year 5th

Year

Total (Rs. In Lakhs)

Proposed Action Plan

1 Drinking water supply to nearby villages.

5.0 4.0 4.0 4.0 4.0 21.0

Proposed to establish RO plant for

drinking water supply to Dondapadu,

Mukteshwarapuram, Bugga Madharam

and Vajinepalli villages.

2 Educational Aid to the school students

2.0 2.0 2.0 2.0 2.0 10.0

Supply of books, uniforms and other

educational aides like computers with

internet facilities to nearby village schools.

3 Medical Camps 3.0 2.5 2.5 2.5 2.5 13.0

Free Health checkup and supply of

medicines to the sick people in the nearby

villages.

4 Self Help Skill Training

2.0 2.0 2.0 2.0 2.0 10.0

Based on local identified needs, we will

set up training centre to impart skills such

as tailoring, toys making, book binding and

basic computer skills to local women and

men

Self help skill Training: Unskilled/

Semiskilled persons will be identified in



S. No CSR & CER

Activity 1st

Year 2nd

Year 3rd

Year 4th

Year 5th

Year

Total (Rs. In Lakhs)

Proposed Action Plan

villages and given necessary training as

per industry requirement and we will

absorb the personnel in industry as and

when need arises

Total CSR & CER Budget

12 10.5 10.5 10.5 10.5 54.0



8.3 DIRECT REVENUE EARNING TO THE NATIONAL AND STATE EXCHEQUER

This project will contribute additional revenue to the Central & State exchequer in the

form of Central GST & State GST. Thus, the proposed project will help the Government

by paying taxes from time to time, which is a part of revenue and thus, will help in

developing the area. Demand of the proposed products in foreign market is also

significant, which will boost the export potential of the company as well as country.

Export oriented units plays vital role in development of economy as well as local

physical infrastructure for further boosting of industrial development with sustainable

approach as the industries need to maintain good environment & safety environment to

get better foreign market.

8.4 IMPROVEMENTS IN THE PHYSICAL INFRASTRUCTURE

The project proponent has proposed to develop infrastructural facilities like roads,

drinking water and power to the proposed site, easily accessible approach roads

required for public transport and material transport to the project site. Hence major

benefit to the public infrastructure is anticipated due to the proposed project.

8.5 IMPROVEMENTS IN THE SOCIAL INFRASTRUCTURE

The proposed project will have many employment & trade opportunities from the

inception of the construction activities. Thus, these considerable employment & trade

opportunities will eventually result in appreciable economic benefits to the local people

& businesses/ contractors and helps to improve in the social infrastructure.

8.6 OTHER TANGIBLE BENEFITS

With this new unit, SGR Laboratories Pvt. Ltd. contributes to growth in manufacturing

sector and the country will also benefit from GST revenues, Foreign exchange earnings

from exports are envisaged. Beside economic benefits, the general social & cultural

development of the area is anticipated due to the CSR & CER activities planned by the

company. The long-term implications of this change can be definitely considered as

progressive development of surrounding area.

ENVIRONMENT COST

BENEFIT ANALYSIS

CHAPTER -IX


Prepared By Rightsource Industrial Solutions Pvt. Ltd Chapter – IX Page 308

CHAPTER - IX

ENVIRONMENT COST BENEFIT ANALYSIS

9.0 COST BENEFIT ANALYSIS

During the scoping stage; no recommendation of environmental cost benefit analysis is

suggested by the appraisal committee.

ENVIRONMENTAL

MANAGEMENT PLAN

CHAPTER -X


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter – X Page 309

CHAPTER – X

ENVIRONMENT MANAGEMENT PLAN

10.1 INTRODUCTION

Environmental Management Plan reflects the commitment of the management to

protect the environment within and outside the industrial premises. An environmental

management plan is required for formulation and monitoring of environmental

protection measures during and after construction / Modification and commissioning

of the projects. Hence, the construction and operational phase is considered for

outlining the Environmental Management Plan for the said industry. The plan

indicates the details as to how various measures have been taken by the industry to

mitigate the pollutants generated due to its operations.

The Potential Environmental Impacts from the construction and operational activities

of the industry are summarized below.

A. Construction / Modification Phase:

Site preparation, sanitation, noise, construction equipment & waste and site

security.

B. Operation Phase:

Air pollution due to emission of Particulate Matter, Sulphur dioxide, Nitrogen

oxide from the boiler stack and D.G. Set.

Gaseous emissions from process leading to workroom air pollution.

Noise pollution due to noise generating equipment operation.

Disposal of effluent generated due to plant operations.

Disposal of Solid Wastes generated due to the plant operation.



FIGURE 10.1: FLOW CHART OF EMP

IDENTIFICATION OF THE

POTENTIAL IMPACTS

RECOMMENDED MITIGATION

MEASURES

DESCRIPTION OF MONITORING PROGRAM

ENSURE COMPLIANCE WITH RELEVANT STANDARDS AND

RESIDUAL IMPACTS

ALLOCATION OF RESOURCES AND RESPONSIBILITIES FOR

PLAN IMPLEMENTATION

IMPLEMENTATION SCHEDULE

AND REPORTING

PROCEDURES

CONTINGENCY PLAN WHEN

IMPACTS ARE GREATER THAN

EXPECTED



10.2 PRE- PROJECT ENVIRONMENTAL MANAGEMENT PLAN

Construction related impacts:

The industry is proposed to establish Bulk Drugs & Intermediates manufacturing unit.

The potential for environment pollution during the construction is obviously

considerably less than when the plant is in operation. The following factors require

control during the construction phase.

10.2.1 Site Preparation

The leveling operation will involve stockpiling of backfill materials. All the disturbed

slopes shall be stabilized with grass cover and dust nuisance controlled.

10.2.2 Sanitation

The site will be provided with sufficient and suitable toilet facilities with proper

hygiene for construction workers. Adequate potable water supply will be provided for

onsite workers.

10.2.3 Noise

The total noise effect in the vicinity during construction stage will be negligible in the

site and the site is far away from the nearest human habitation.

10.2.4 Construction Equipment and Waste

It will be ensured that construction related vehicles are properly maintained to

minimize exhaust emissions. Combustible waste will be burnt in a controlled manner.

Other wastes will be disposed off in to a dedicated dump. Spent liquid waste if any,

arising from chemical treatment of built-up portions for termite etc., will be correctly

neutralized and disposed off.

10.2.5 Site Security

The site will be secured by fencing and manned at entry points.

10.3. ENVIRONMENTAL MANAGEMENT DURING OPERATION

10.3.1 AIR QUALITY

The emissions from boilers & D.G. Set are the sources likely to contribute to air

pollution. Adequate measures are being taken to minimize the impacts of these

emissions on the environment.



The baseline data collected during the study period indicate that all seven pollutants

namely PM2.5, PM10, SO2, NOX, CO, NH3 and VOCs.


boilers.

The coal requirement of 15.5 TPD will be met from local authorized sources.

A 500 KVA DG set is proposed for this project for usage during the power failures.

The industry proposed to install 3 x 200 TR & 1 x 300 TR cooling towers.

10.3.1.1 AIR POLLUTION CONTROL / MANAGEMENT

Following are the proposed pollution control schemes and which will be used to

minimize and control the emission of air pollutants as well as their effective

dispersion into the atmosphere.

A. Stack Design

The stacks of height 30 mtrs each with controlling equipment (cyclone separator

followed by Bag Filters) will be provided for the coal fired boilers with the

approximate flue gas exit velocities of 12 m/s & 14 m/s ensures proper dispersion of

the flue gas into atmosphere. This design will ensure the ground level concentration

of the pollutants to comply with the ambient air quality standards.

DG Set Stack emission Controlled by providing adequate stacks height to disperse

into atmosphere and maintain the air pollutants within the limits prescribed by CPCB.

B. Fugitive Emissions from Solvents

Various types of solvents will be used in the proposed Bulk Drugs & Intermediates

manufacturing process. The solvents will be stored in drums and Bulk quantities will

be stored in storage tanks with vent condensers. These are handled in closed

conditions thereby reducing the losses in the form of evaporation. The industry will

take measures for reduction of fugitive emissions by providing Chilled brine

circulation to the condensers, which ensures the recovery of 95% and also controlled

by closed operations and handling methods. Good ventilation will be provided to

reduce the workroom concentrations. The reactor generating solvent vapors will be

connected to condensers with receivers.



C. Storage and Transportation of Raw Materials

The Raw materials / chemicals will be received in Fiber drums, HDPE drums, PP

bags by trucks. The same will be stored in ware house under lock & key

arrangement. Slight increase of Ground level Dust and VOC in air and it can be

minimized by developing Greenbelt in and around the plant premises and providing

proper roads for transportation.

10.3.2 NOISE POLLUTION

All the equipment in the plant would be designed as per the requirement of CPCB

standards.

NOISE ENVIRONMENT

Compressors, Boiler and DG set will be the major noise generating units in the plant,

of which generator will be functioning only at the time of power failure. There is no

need for the workers to be near the DG set & compressor units continuously. The

Generator sets will be placed in acoustic enclosures to maintain the noise levels as

permitted by CPCB.

NOISE POLLUTION CONTROL / MANAGEMENT

The noise levels in the work place environment will be monitored periodically

and if necessary action will be taken in the form of regular maintenance

schedule to reduce noise and vibration in generating sources.

The effects of the vibrations coming out of the base of the body over the

surrounding civil structures are minimized by providing Damping pads/Resilient

mounting at the time of installation.

Under the general health check up scheme as per factory act, the workers will

however be checked up for any Noise induced Hearing Loss (NIHL) by a trained

ENT Doctor.

10.3.3 WATER QUALITY

Water is essentially used in process, Boiler and for cooling tower along with

domestic purpose. The total water required for the plant operations will be met from

Ground Water source.



WATER POLLUTION CONTROL / MANAGEMENT

The effluent generation is from process, boiler blow down, Scrubbing System, Floor

& Reactor washings and Domestic sections.

The unit will provide proper wastewater collection and Treatment methods to

treat the trade effluent in the plant premises.

Process effluent will be segregated based on COD & TDS concentration and

collected separately by gravity from all sources into a collection Pit.

Collected waste water will be pumped in to the above ground level tanks

separately.

The industry by opting ZLD treatment system to recover water for recycle and

reuse for plant operations and to conserve the scarce resource of water.

Treatment system

The effluent will be neutralized, the HTDS/ HCOD effluent will be sent to

steam stripping Column for collection of Organic distillate which is mixed in

the waste water stream. After stripping, effluent will be sent to Multi Effect

Evaporation System, Stripped Organics collected and sent to cement industry/

TSDF incinerator.

The concentrate from the MEE System will be sent to ATFD and salts from

the ATFD will be collected and sent to TSDF for safe disposal.

The condensate from MEE followed by ATFD sent to biological system for

Treatment.

The LTDS effluent along with MEE / ATFD condensate will be sent to

Biological treatment, treated effluent sent to RO for water recovery.

The RO permeate will be reused and RO reject will be sent to MEE followed

by ATFD for further evaporation. MEE condensate collected along with RO

permeates for reuse. Salts from ATFD collected and sent to TSDF.

All the treatment tanks etc. is constructed only with acid proof tiles and 1.5 to

2.5 meters above the ground Level.

Roof Water Harvesting System will be put in practice to recharge the ground

water.



Strategic Control / Management

Minimizing water usage.

Segregation and collection of effluent for proper treatment and to minimize

waste generation at treatment facility and to recover water for recycle and

reuse.

Reducing the water consumption for the process by way of developing the

process and operation methods.

Prepare SOPs for handling and treatment of effluent water.

Minimize spillage and leakage of effluent to avoid Land pollution.



FIGURE 10.2: SCHEMATIC DIAGRAM OF PROPOSED WASTE WATER TREATMENT- ZLD SYSTEM

*Water recovery from ZLD system is 43.50 KLD

HTDS Effluent

19.18 KLD

Stripper

MEE 18.80 KLD

ATFD

Salts to TSDF

Organic Distillate to Cement Industry

0.38 KLD

Vapor Condensate@80%

15.04 KLD

LTDS Effluent

33.68 KLD

BTP

48.72 KLD

Losses @5%

2.44 KLD

MEE 13.88 KLD

ATFD

RO System

46.28 KLD

RO permeate for Reuse

@70% 32.40 KLD

RO Reject to

MEE 13.88 KLD

Condensate

@80% 11.10 KLD

Water for Reuse

43.50 KLD

Salts to TSDF



FIGURE 10.3: FLOW CHART FOR EFFLUENT TREATMENT HTDS



FIGURE 10.4: FLOW CHART FOR LTDS EFFLUENT TREATMENT LTDS



10.3.3.1 DETAILS OF ZLD SYSTEM

All the effluent generated from the plant are collected in the Effluent collection pits

and from those pits effluent will be pumped to the above ground storage tanks

through the closed HDPE pipe lines. All these effluent collection pits are lined with

acid proof tiling or HDPE lining.

The Industry will construct the above ground storage tanks to store the collected

effluent from various streams. The tanks consist of 6 Compartments and are used to

store the HTDS in two compartments and LTDS in four compartments effluents

separately. These tanks can accumulate more than 4 days generation of effluent.

The HTDS effluent consists of COD will be sent to the Stripping Column for the

removal of same and thereafter the effluent will be sent to the MEE system which

consists of 3 Calendrias and the condensate will be collected. The concentrate will

be sent to ATFD for separation of salts. The condensate collected from MEE &

ATFD sent to ETP for treatment. The salts generated from the ATFD will be stored &

disposed to TSDF for secure Land Fill.

Now, the Condensate water from the MEE system along with the LTDS effluent will

be sent to the ETP system for the removal of BOD etc., The ETP system consists of

Aeration and Clarification. After this the treated effluent from biological system is

passed through the Sand Filter, Carbon Filter and Micron Filters and finally sent to

RO System.

70% water recovered as RO permeates. Remaining 30% reject water will be sent to

MEE followed by ATFD system for Evaporation. In this ZLD treatment we can

recover 70% of the water for recycle and reuse in the plant Utilities.

Figure 10.5: FLOW CHART FOR EFFLUENT TREATMENT

Effluent Type Treatment Flow

HTDS

Collection Equalization & neutralization Stripper MEE ATFD TSDF MEE/ATFD Condensate sent to Biological Treatment followed by RO.

LTDS

Collection ETP (Biological Treatment) Sand Filter Carbon Filter Cartridge Filter RO Plant RO Reject to MEE. RO Permeate for Re-usage.



10.3.3.2 THE TECHNICAL DETAILS OF THE SYSTEMS ARE AS FOLLOWS:

MEE System Capacity: 40 KLD

RO System Capacity: 50 KLD

10.3.3.3 MEE PLANT CONFIGURATION

Part – A: Stripper Unit with Flash Condenser, Re boiler and Recirculation Pump

Part–B: Triple Effect Forced Circulation Evaporation Plant with Thermo

Compressor, Required Equipment & Components.

Part – C: Agitated Thin Film Dryer

10.3.3.4 PROCESS DESCRIPTION (Part – A)

1. Feed will enter to the series of Pre heaters of Evaporator P4, P3, P2 and then

P1 using Feed Pump. From Discharge of Feed Pump Feed will be heated

through Series of Pre heater using Vapour from Jacket of respective

Calendria. Feed will be heated to the boiling point and will enter to the

recirculation loop of Stripper.

2. Recirculation Loop of Stripper will comprise of Flash Vessel, Recirculation

Pump and Re boiler.

3. Feed coming out from Pre heater of Evaporation Plant will re-circulated

through boiler and heated up using Steam.

4. Heated Feed will allow flashing in Flash Vessel and by flashing high volatiles

and Water will convert to vapour. Vapour will travel from bottom to top of

Stripping column where feed liquid will flow from top to bottom. Random

packing inside the stripping column provide mass transfer surface to vapor

liquid interface.

5. Rich organic vapour with some water vapour will come out from the top of

Stripper column. This vapour will be condensed in Flash Condenser at the top

of Stripper column.

6. Condensed organic rich liquid will be collected in Reflux pot from condenser.

From Reflux pot partly it will be withdraw according to the desired Water

Vapour/ Organic ratio and remaining will enter to the column as reflux.



10.3.3.5 PROCESS DESCRIPTION (Part - B)

1. From Discharge of Stripper recirculation Pump feed will enter to the

Evaporation Plant. Feed will enter to the Evaporation Plant from Discharge of

recirculation pump of Stripper.

2. First Effect is a Forced Circulation Type comprising of Calendria-1, Vapour

Separator-1 and Recirculation Pump– 1. Liquid will re-circulate continuously a

through Calendria Tubes at high velocity and will get heated using Heat of

Condensation of First Effect Jacket. This Heated Mass will allow flashing in

Vapour Separator and Water Vapour being generated.

3. This Flash Vapour will partly recompressed to the Jacket of First Effect using

Thermo compressor which will convert high pressure motive steam to low

pressure and will create suction and take part of the water vapour from

Vapour Separator -1.

4. Condensate from Jacket of First Effect will travel to 2nd Effect using pressure

difference available between these two Jackets.

5. Concentrate will be coming out from 1st Effect will be sent to Balance Tank -1

which will be placed between 1st and 2nd Effect.

6. Second Effect also is a Forced Circulation Type comprising of Calendria-2,

Vapour Separator-2 and Recirculation Pump– 2. Liquid will re-circulate

continuously a through Calendria Tubes at high velocity and will get heated

using Heat of Condensation of Second Effect Jacket. This Heated Mass will

allow flashing in Vapour Separator and Water Vapour being generated.

7. Concentrate coming out from 2nd Effect will be below saturation level and

there will not be any crystallization takes place in 2nd effect.

8. This Heated Mass will allow flashing in Vapour Separator and Water Vapour

being generated.

9. Concentrate will be coming out from 2nd Effect will be sent to Balance Tank -2

which will be placed between 2nd and 3rd Effect

10. Condensate coming out from 3rd Effect Jacket is a mixture of Steam utilized in

Thermo compressor and Evaporated Water Vapour from 2nd and 3rd effect.

Condensate will be taken out from plant using Condensate Outlet Pump and

send for Storage.

11. Concentrate from Evaporation will be taken out from the Plant using

Concentrate Outlet Pump and send to ATFD.



12. Water Vapour from Last Effect will be condensed in surface type condenser

using Cooling Water as condensing media. Steam Jet Ejectors/ Water ring

Vacuum Pump will maintain vacuum in the plant back to the condenser.

10.3.3.6 PROCESS DESCRIPTION (Part - C)

1. Feed Pump will be gear/ roto type pump to handle viscous Feed. Feed will not

required to preheat as it will come at 85-90 Deg C from the tank. Feed will

enter to the Vertical ATFD first for initial evaporation. Feed will splash to the

Heat Transfer Surface of ATFD using liquid distributor.

2. V-ATFD will be a hollow cylindrical Jacketed Vessel having Agitator and

specially designed Scrapper blades to wipe out the Surface of ATFD all the

time to keep it clean. This will maintain consistent performance of ATFD for a

long time.

3. ATFD Scrapper will rotate at medium RPM using Gear Box for reduction of

RPM which will be govern by Variable Frequency Drive.

4. ATFD Heat Transfer Surface will be heated through Steam in Jacket. Vapour

outlet will be connected with Entrainment Separator to avoid product

contamination in Condensate. Vapor will be condensed in Condenser and

Negative draft will be maintained by Water Ring Vacuum Pump.

5. Product coming out from bottom of Vertical ATFD. Steam will be applied in

Jacket of same to allow the product dry.



FIGURE 10.6: SCHEMATIC DIAGRAM OF MEE SYSTEM



10.4 HAZARDOUS / SOLID WASTE MANAGEMENT

Generation of hazardous / Solid Wastes

The hazardous / solid waste generation from process, spent carbon, used oils, ETP

sludge, Evaporation Salts, ash from boiler; will be sent to TSDF/Cement plants/Brick

manufacturers as per respective waste category.

Resource Conservation / Waste Minimization

The unit will also implement the concept of waste minimization circle including:

Volatiles in the by-products will be condensed and reused.

Volatile raw materials will be separated by rectification and these can be

recycled into process.

Good House Keeping practices make the system easier and less costly.

Some of these are as follows:

Solid wastes e.g. powders, spills, etc. in process, and packaging will be

separately collected and disposed off instead of allowing these to join

effluent streams. This will reduce load and increase the efficiency of

treatment system.

Search for future recycling schemes and evaluate their worth and

implement such schemes wherever a promise of economic feasibility

exists.

Discarded Container / Barrels/ Liners Management

Discarded containers/ barrels/ liners will be kept at a designated place

with paved surface.

These will be decontaminated (washed/ cleaned) and stored in the

designated area in scrap yard. Washed water sent to ETP.

These will be sold to the actual users/ recyclers as per the Hazardous

Waste (Management, Handling and Transboundary Movement) Rules,

2016.

The record of discarded containers/ barrels/ liners stored in scrap yard

shall be maintained and also, inventory of their selling to the registered

recyclers shall be maintained. The same shall be reviewed by the HSE

Department of the project.



Handling of Solid Waste and Hazardous Waste

The solid wastes and hazardous wastes will be packed in double lined

PP bags and stored in dedicated area. As and when sufficient stock is

accumulated, Organic Waste will be sent to Cement Industry for

incineration and Inorganic waste will be sent to TSDF for further

treatment and safe land fill.

Industry will enter into an agreement with concerned Hazardous Waste

Management unit.

10.5 EB [ECOLOGY & BIODIVERSITY]

The project activity does not require tree cutting. Also, the study zone does not have

any ecologically sensitive location and hence, the plant activities are not expected to

have any impact on ecology and biodiversity.

Air emissions, liquid effluent disposal and solid waste generation are likely to have

some impact on terrestrial ecosystems. However there will be no net increase in air

pollution.

Proponent will develop greenbelt around 37.51% of its total area.

Management

Raw material dispensing stations will be equipped with vacuum duct

hoods with top cover.

All tanks vents being used for storage flammable chemicals will be

connected to respective condensers to avoid VOCs in the plant area.

10.6 SE [SOCIO-ECONOMIC ASPECTS]

This project will have positive impacts on Socio-Economic Environment.

Positive impacts

Direct employment generation potential of the project will be for about 100

persons, wherein the first preference will be given to the Qualified People

from within the Study Area.

Various modes of indirect employment i.e. providing Conveyance,

Transportation, Goods and Services will also increase.



Overall improvement in quality of life of people of the study area will

increase.

10.7 HG [HYDROGEOLOGY, GROUND WATER & WATER CONSERVATION]

The proposed project is located on the divide portion of the catchment and is over

the run off zone. No major streams are passing through the site. The catchment area

of the plant site is small and recharge conditions are moderate. However, the buffer

zone of 10 km radius has good catchment and recharge potential with streams and

tanks of considerable storage potential.

All the stream courses are ephemeral in character and carry large volumes of storm

flows during rainy season and remain dry during non - monsoon season. The width

of the streams is narrow and follows the weak planes within the hard rock

formations.

Ground Water Conditions

Groundwater occurs under semi-confined conditions in the fissured zone of the

banded biotitic hornblende gneisses. Ten bore wells were inventoried to assess the

groundwater conditions. The depth to water levels was found to be 8 -132 m bgl. The

yield ranges of bore wells were found to be 1-3 lps. The quality of water is found to

be potable.

As the extent of the proposed site is very small only roof top rainwater harvesting is

suggested for improving the recharge to the groundwater.

The proposed area is categorized as safe by the Groundwater department and

scope for development & stage of groundwater is good. The site is feasible for

groundwater extraction for the proposed Bulk drug intermediates manufacturing unit.

Possible Impacts on Groundwater & Mitigation

The generation of ash from the industry will have sedimentation affect over

the wind ward side on the soil regime as well as the buffer zone over a period

of time affecting the flow rates of water.



The chemically loaded waste water leakage from the industry may affect the

soil, surface and groundwater sources, so we will closely monitor to avoid any

spillage or leakages.

The ash spreading in and around the plant will be avoided by storing under

closed conditions at dedicated place till it is disposed to users. The prevention

suggested is not to allow the waste water leakage from the industry by

implementing proper storage tanks for wastewater collection and ZLD system.

Ash generation and storage will be monitored closely to avoid leakages and

will be disposed safely to the brick manufacturing industries and infrastructure

projects.

All the chemically charged liquid discharges will not be allowed to be in

contact with surface/ groundwater.

10.8 GEO [GEOLOGY]

The district is underlain by variety of geological formations comprising from the

oldest Archaeans to Recent Alluvium.

10.9 SC [SOIL CONSERVATION]

The proposed project does not have any impact on the soils beyond the boundaries

of the project site and it is a Zero Liquid Discharge Unit; the chances of any

enhanced soil erosion are not anticipated. But improper disposal of toxic wastes and

accidental spillages of toxic chemicals can pose a serious threat to the soil, ground

and surface waters. But the chances of such events cannot be quantified and

predicted. Since the industry is expected all rules and regulations relating to the use,

handling and disposal of all toxic and hazardous chemicals, no additional safety

methods are required especially to prevent contamination of soil. Liberal use of

locally available farmyard manure will be used for the plants in the greenbelt and

block plantations for improving the productivity, fertility and health of soils.

The project does not have any impact on the soils beyond the boundaries of the

project site since it is a zero liquid discharge unit.

Physicochemical characteristics of the soil samples obtained from 7 areas in the

buffer zone and one from the project site reveals that all basically sandy loams.



10.10 RH [RISK & HAZARDS MANAGEMENT]

All the provisions as per the Factories act, 1948 manufacture, storage and import

of hazardous chemicals [MSIHC] Rules, 1989 and amendments thereafter and

also, the Hazardous Waste (Management, Handling and Transboundary

Movement) Rules, 2016 will be followed.

Work environment monitoring as well as noise monitoring will be carried out on

regular interval through third party.

Following hazards may occur during the operation.

Fire Hazards

Chemicals handling and Storage

Road accidents

Process hazards

Health hazards

Following procedures will be followed for effective management of any disaster in

the plant.

Identification of Hazards and Risk assessment

Identification of persons at risk

Mitigation measures to minimize or elimination of Risk

Disaster management plan

10.11 GREENBELT DEVELOPMENT

10.11.1 OBJECTIVE

The purpose of a green belt around the plant site is to capture the fugitive emissions

emanating from Plant operations, attenuate the noise generated and improve the

aesthetics.

Environmental protection has been considered as an important domain for industrial

and other developmental activities in India. Ministry of Environment, Forest and

Climate Change (MoEF&CC) has taken several policy initiatives and promoted

integration of environmental concerns in developmental projects. One such initiative

is the notification on Environmental Impact Assessment (EIA) of developmental

projects issued in 1994 and further revised notification in year 2006 under the

http://greencleanguide.com/tag/moef/





provisions of Environment (Protection) Act, 1986 EIA Guidance Manual for building,

construction, townships and area development projects proactively talks about the

importance of greenbelts in such projects.

Greenbelt in India refers to a buffer zone created beyond which industrial activity

may not be carried on. This concept has developed through a long line of cases and

today, greenbelts are present not only for the purpose of protecting sensitive areas

to maintain ecological balance, but are also be found in urban areas so as to act as a

sink for the harmful gases released by vehicles and industries operating in the city

area. In this regard, comprehensive Guidelines for Developing Greenbelts have been

compiled by the Central Pollution Control Board.

10.11.2 ACTION PLAN

As per the stipulations of MoEF&CC, greenbelt is to be provided all along the

boundary by planting tall, evergreen trees and the total green area including

landscaping area will be about 37.51% of the project area. There are block

plantations within the project site. Typical industrial greenbelt on all sides of the plant

site with 5 to 10 m width patches and strips of greenbelt with a spacing of 2m x 3 m

(1500 trees per Ha). About 1965 trees will be grown in the space available in the

project area. Since there will be two rows of trees, they get direct light at least from

one side and the branches can expand. Hence, potentially large trees with wide

canopy are chosen instead of the less branched and straight growing trees. In

addition to greenbelt development in the plant site, proponent proposed to develop

green area with trees such as fruit bearing, Neem, Kadamba plantations of 1000

trees/year for five years in the nearby three identified villages (Dondapadu,

Mukteshwarapuram, Bugga Madharam and Vajinepalli). Soil is good and suitable for

plant growth but water supply is critical during the dry season. Special care shall be

taken to water them at least once in 3 days during the dry period. A list of plants

suitable for greenbelt and to the local agro climatic conditions.

A list of multipurpose trees proposed to be planted in the greenbelt is given in Table

10.1.



TABLE 10.1: List of Plants Identified For Greenbelt and Avenue Plantations

Botanical name Local or common

name Importance

Acacia auriculiformis Australian wattle Avenue tree

Albizia lebbeck Dirisana Shade and timber

Azadirachta indica Vepa or Neem Neem oil & neem products

Conocarpus lancifolius Lanceleaf button wood Evergreen drought resistant naturalized tree

Dalbergia sissoo Sissoo Avenue and timber tree

Dendrocalamus strictus Bamboo Bamboo products

Grevellea robusta Silver Oak Erect non-shedding tree

Holoptelia integrifolia Nemali naara Fibre and timber

Leucaena leucocephala Subabul Fodder and pulp wood

Mangifera indica Mango Edible fruit

Mimosops elengi Pogada Shade and edible fruit

Muntingia calabura Wild cherry Shade and edible fruit

Pongamia pinnata Gaanuga Source of biodiesel

Polyalthia pendula Ashoka Majestic tree

Polyalthia longifolia Ashoka Avenue tree

Samania saman Nidrabhangi Shade, timber & fodder.

Spathodea companulata Flame of the forest Ornamental avenue tree

Syzygium cumini Neredu Edible fruits

Tamarindus indica Chinta Tamarind fruit and leaf

Terminalia arjuna Nallamaddi Timber and shade tree

Terminalia catappa Baadam Edible nuts

Terminalia mantaly Madagascar Almond Beautiful avenue tree

10.12 POST PROJECT MONITORING

Regular monitoring of all significant environmental parameters is essential to check

the compliance status vis-à-vis the environmental laws and regulation. The objective

of the monitoring will be as follows.

To verify the results of the impact assessment study with respect to the

proposed project.

To study the trend of concentration values of the parameters, which have

been, identified as critical and planning the mitigate measures.

To check and assess the efficacy of pollution control equipment.

To implement the EMP, a structured Environment Management Cell (EMC)

interwoven with the management system will be created.

EMC will undertake regular monitoring of the proposed pollution control

system and conduct yearly audit of the environmental performance of the



system. It will also check that the stipulated measures are being satisfactory

implemented and operated.

A comprehensive environmental monitoring program that will be prepared for the

purpose of implementation in the proposed manufacturing unit by the EMC is

described below.

10.12.1 AIR POLLUTION MONITORING

The Stack emissions from boilers & DG Set will be monitored once in a month for

PM10, NOX & SO2. The ambient air at the plant site will be monitored once in a month

for PM10, NOX & SO2. The Fugitive Emissions like VOC’s will be monitored in

Production block, Raw Material and Finished goods section.

10.12.2 WASTE WATER MONITORING

The quantity of waste generated from ETP unit will be regularly measured using flow

meters. Wastewater samples will be collected and analyzed for critical parameters

like pH, TDS, BOD, COD, Oil and Grease, Chlorides, Sulphates etc.,

10.12.3 GROUND WATER MONITORING

Ground water quality of bore well will be regularly monitored preferably once in a 6 /

12 months.

10.12.4 HAZARDOUS / SOLID WASTE MONITORING

Hazardous / Solid waste generated from the plant will be monitored once in a

month/change of the product.

Table 10.2: The Details of the Monitoring Program

S. No

Type of Monitoring

Location of Monitoring

station

Frequency of

Sampling

Duration of

Sampling Instrument

Parameters to be tested

1 Ambient Air 3 Places at 120o angle

Once in a month

8 hrs/ 24 hrs

RDS PM10, SO2 & NOX

2 Work room concentration

Production Block, Store rooms

Once in 3 Months

--- Personal Sampler

VOCs

3 Stack Monitoring

Boilers, D. G. Set, Scrubber vents

Once in a month

--- Stack Monitoring Instrument

PM10, SO2, NOX and Scrubbing gases.



4 Noise Levels

D. G. Set, Compressors, Chillers, Boilers section, Production block, Admin. block, ETP area, Open area etc.

Once in a month

--- Noise meter

Day – Night Noise levels in Leq

5 Effluent

Raw HTDS & LTDS effluent, Condensate, Treated wastewater

Daily --- Internal & External Lab

Physical and Chemical Parameters

6 Ground water

Nearest Bore well

Once in six months

---

7 Solid Waste Sludge from Process, ETP

Once in six months

---

All the above observations will be complied and documented by the EMC to serve

the following purposes.

Identification of any environmental problems that are occurring in the area.

Initiating or providing solution to those problems through designed channels

and verification of the implementation status.

Controlling activities inside the plant, until the environmental problem is

corrected.

Suitably responds to emergency situations.

The industry will engage recognized laboratories to carry out all necessary

monitoring parameters. Qualified staff will be appointed for the purpose of Operation

and maintenance of the pollution control facilities. Stand-by facilities are provided to

all the facilities so as to ensure fail proof treatment.

10.13 MANAGEMENT OF PUBLIC INTERESTS

10.13.1 OBJECTIVE

To assure the neighboring communities that the promoters and management have

high consideration for the welfare of this region, the following commitments are made

by the project promoters.



10.13.2 PREFERENCE TO LOCAL POPULATION

For the recruitment of semi-skilled and unskilled workers preference will be given for

the local people.

10.13.3 HEALTH CAMPS

Health camps will be organized along with the local administration and voluntary

organizations like Red Cross, Rotary Club etc., in the surrounding villages.

10.13.4 PUBLIC AMENITIES

The management will support the local administration with funds and other forms of

assistance for the development of public amenities in this region.

10.13.5 PUBLIC RELATIONS

The management will set up a public relations office to maintain to good line of

communication between the management and the public on matters of

environmental concern.

10.14 WATER REQUIREMENT

Proposed Water Consumption Details

Table 10.3: Proposed Water Consumption Details

S. No Purpose Water input

KLD

1 Process 25.13

2 Washings 5.00




6 Domestic 5.00

7 Gardening 3.00

Total 134.13



10.15 PROCESS EMISSION CONTROL SYSTEM

a) No. of scrubbers and capacity: 2 No. scrubbers installed.

1 No: 300 mm (Diameter) X 3 meters (Height)



b) Type of scrubber: Scrubber material of construction is PP+FRP with one inch poly

propylene rings as packing material with a circulation pump.

c) Chemical used in scrubber: Alkali solution

FIGURE- 10.7: SCHEMATIC DIAGRAM OF EMISSION CONTROL SCRUBBING

SYSTEM

10.16 FUGITIVE EMISSIONS

Various types of solvents will be used in the manufacturing process. The solvents

will be stored in storage tanks with vent condensers. These are handled in closed

conditions. The industry will take measures for reduction of fugitive emissions by

providing chilled brine circulation to the condensers which, ensures the recovery of

95%. Good ventilation will be provided to reduce the workroom concentrations. The

reactor generating solvent vapors will be connected to condensers with reflux

system. Dyke walls will be provided to the solvent storage tanks. The solvents like

Ethyl acetate, Methanol and Toluene will be recovered up to 95 % by using

distillation and the remaining 5% will be the loss.

10.17 SOLVENT MANAGEMENT PLAN

Solvent management consists of the following:

Unloading

Storage



Handling / transferring

Process / Reaction

Recovery

i) Unloading

Solvents are received in drums / tankers

Drums

Before unloading the drums from the truck, check the drums condition.

Drums may be MS or HDPE Carboys

Drums / barrels will be unloaded from the vehicles onto the unloading platform

by using the drum lifter provided for the purpose. Under no circumstances

drums shall be dropped or rolled on the ground or on any other material

Carboys will not be dropped or allowed to strike against each other and shall

be unloaded on the pallets

Personal protective equipments like safety goggles, hand gloves, PVC aprons

and safety shoes will be used while handling chemicals.

Road tankers

Security will ensure that vehicle personnel shall not carry any match box /

lighters

The store personnel, has to check the paper work before unloading to confirm

that the correct chemical received as well as discharged into the dedicated

tank.

Barriers and flags should be positioned to warn personnel at the unloading.

Brakes should be set and the wheels chocked.

The truck should be earthed.

Tanker should be kept under inert gas flushing through vent while unloading

Make sure that the inert gas valve remains open during the entire unloading

period of delivery is by gravity or by pumping.

Connect the flexible hose to the tanker and to the transfer pump

Check liquid level gauge on storage tank to ensure liquid is being transferred

When tanker is empty, stop pump and close valves on tanker, close valves in

transfer line.

[For flammable material, stop inert gas purge]



Disconnect flexible hose and put into proper catch container to ensure no

product is lost on to the ground.

Remove choked warning signs, earthing and switch locks

Read storage tank liquid level gauge and record reading

ii) Storage/ handling/ transferring

Storage Tanks

2 or 3 Square meter condenser [depends on solvent volatility] with cooling

water circulation is connected to each solvent storage tank to prevent solvent

vapors escaping from tank surface in to atmosphere. The condensed solvent

will go to respective tank. This results in recovery of solvent and prevention of

VOCs into the atmosphere.

The solvent pump which is having mechanical seal will be used for

transferring the solvent to the Day Tank of the respective reactor as and when

required. The entire solvent transfer takes place in a closed system. There is

no manual handling.

The above management will results in recovery of solvent more than or equal to

95%.

Drums

As and when required the solvent drums in closed condition will be transferred

to the respective reactor.

By using AODD pump the solvent will be transferred in to the reactor. Hence,

there is no loss of solvent during transfer.

iii) Reaction /Recovery

During reaction stage the solvent vapors will be sent to a primary condenser

having cooling water circulation and later to secondary condenser having

temperature < 50 C chilled brine circulation.

Above system will eliminate solvent losses during reaction stage and recovery

will be the maximum extent possible.

The above management will results in recovery of solvent more than or equal to 95%.



Chlorinated solvents

Solvent drums will be stored in ware house below 25 ⁰C

As and when required the solvent drums in closed condition will be transferred

to the respective reactor. By using AODD pump the solvent will be transferred

in to the reactor. Hence, there is no loss of solvent during transfer.

During reaction stage the solvent vapors will be sent to two primary

condensers which are arranged in parallel having cooling water circulation

followed by a secondary condenser having brine circulation at temperature of

5 ⁰C.

System will eliminate solvent losses during reaction and recovery will be the

maximum extent possible.

The above management will results in recovery of solvent more than or equal to

95%.

10.18 EMISSIONS – UTILITIES



The unit is proposing 500 KVA DG set, for usage during the power failures.

The emission details are presented in below Table 10.4 & 10.5

Table 10.4: Characteristic Details of Proposed Boilers



Boiler


5000 kcal/kg


5000 kcal/kg


Ash Content % 35 35







Particulate Matter gm/sec 0.16 0.15





Table 10.5: Stack Emission Details of Proposed DG Set

Capacity In KVA




Stack dia. In m

Flue Gas Temp. in

OC

Stack Height in (m)


500 KVA 60 85 110 0.2 300 10 14

10.19 WASTEWATER LOADS

The waste water generation will be 52.86 KLD which is from process, floor & reactor

washes, cooling tower blow down, boiler blow down, scrubber, DM plant and

domestic usage. The effluent generation and its HTDS & LTDS effluent details are

given below.

Table 10.6: Effluent Generation Details

S. No Purpose Effluent in KLD

1 Process 28.36

2 Washings 5.00


4 Cooling towers blow down

7.00


6 Domestic 4.50

Total 52.86

Table 10.7: HTDS & LTDS Effluent Details

Unit HTDS KLD

LTDS KLD

Effluent Generation


Process 16.18 12.18 28.36 HTDS Effluent sent to stripper

followed by MEE system.

LTDS effluents treated in ETP along with MEE condensate. Treated effluent is sent to RO, RO permeate water is recycled and RO rejects taken for evaporation in MEE followed by ATFD to collect evaporation salts for disposal to TSDF.

Washings 0.00 5.00 5.00




Domestic 0.00 4.50 4.50

Total 19.18 33.68 52.86

The pollution loads for various pollutants viz., TDS, In-organics, Organics; COD for

proposed products has worked out based on the material balance.



10.20 STAGE WISE EFFLUENT CHARACTERISTICS

The stage wise effluent characteristics have been arrived for the proposed products

based on the material balance, which is given in Chapter-II.

10.21 HAZARDOUS & SOLID WASTE DETAILS

Solid Waste Generation Details

The Hazardous & Solid waste generated and disposal methods from proposed


Table 10.8: Hazardous & Solid Waste Generation, Disposal Details




1406


2 Spent Carbon 71



380



8 MEE Salts 2868




Solid Waste Details


Hazardous & Solid waste will be segregated. Detoxified containers, HDPE

Drums/Bags will be stored in the covered and raised platform with Leachate

collection system and disposed to authorized parties. Non- incinerable solid waste

will be disposed to TSDF for secured landfill.

The Hazardous & solid waste will be disposed off through 7-copy manifest system

within 90 days from the generation. All records will be maintained properly.



10.22 PROPOSED ROOF WATER HARVESTING

To augment the declining ground water levels and water harvesting is the need of

the hour.

Rainwater harvesting is a mechanism involved in collecting, storing and using. A

rainwater harvesting system comprises various stages – flow of rainwater through

pipes or drains, filtration and storage in tanks for reuse or recharge. There are five

components in rainwater harvesting namely catchment, conveyance, filtration,

storage and recharge.

Roof top area is considered for harvesting rainwater for this project and other areas

are excluded due to possibility of chemical contamination. Roof top rainwater

harvesting is one of the appropriate options for augmenting ground water recharge/

storage in urban areas where natural recharge is considerably reduced due to

increased urban activities and not much land is available for implementing any other

artificial recharge measure. Roof top rainwater harvesting can supplement domestic

requirements in rural areas as well.

Design of Roof Water Harvesting Structure

Quantity of Rain water collection and recharging depends upon

Average rainfall

Catchment area

Run-off coefficient

Infiltration rate

Evapo Transpiration

Porosity

Permeability

Generally used Rain water harvesting structures are like Recharge Pits, Invert Well,

Surface storage pond (where areas are large and Optimum rainfall), Check Dams,

Nalla Bunds.

The rain water from the Roof top will be collected through PVC pipes and transferred

to the proposed roof water harvesting pits through steps of eliminating suspended

particles, oil & grease through finally to the ground.



Since the area of harvesting is small the above parameters are not studied in detail

and only applicability as to conserve and harvest the available quantum is

considered and suitable structure suggested Based on IMD Climatological Normals,

1981-2010.

Normal Annual Rainfall = 982 mm (0.98 m)

Table 10.9: Available Rainwater (Annual) for Harvesting

Description Area (m2) Rainfall

(m/Annum)

Runoff

coefficient

Total Rainwater

(m3/Annum)

Roof Area 8998 0.98 0.8 7054.43

Total available rainwater (in m3/annum) 7054

Details of Roof water harvesting pits:

Size of pits 8m x 4m x 3m

Size of Bore 350 mm dia.

Size of pipe 150 mm dia.

FIGURE-10.8: ROOF WATER HARVESTING STRUCTURE



10.23 INVESTMENT

The proposed total gross investment in Buildings and Plant & Machinery will be

approximately Rs. 12 Crores. Industry will allocate an amount of about Rs.110

Lakhs for Environmental Protection measures. Recurring cost will be about Rs. 15

Lakhs per annum.

10.23.1 BUDGETARY ALLOCATION

The management will be set aside adequate funds in its annual budget to fully meet

the stated objectives of the environmental policy. The capital equipment for

environmental management include effluent treatment plants, pipelines and channels

for waste water discharge, green belt development and the environment laboratory.

Table 10.10: Proposed Budget for Environmental Management Plan [EMP]

S.

No Particulars

Proposed

Capital Cost

(Rs. Lakhs)

Recurring

Cost

(Rs. Lakhs)

1

Pollution Control Equipment

(Scrubbers, Cyclone separator, Bag filter,

Sampling port arrangements etc.,)

20.0 2.0

2 ZLD System

(MEE, RO, ETP system) 80.0 7.5

3

Rain Water Harvesting

(Roof top water collection pit and Roof top

water towards the rain water harvesting pit)

3.0 0.5

4 Green Belt Development

(Plantation and Maintenance) 4.0 2.0

5

Health & Safety

(PPEs, Medical Surveillances Expenses

etc.,)

3.0 1.0

6


(Air, Water, Noise, VOCs, Boiler Stack flue

gases, DG sets stack monitoring expenses

etc.,)

0.0 2.0

Total 110 15

10.24 MITIGATION PLAN

There will be few gaseous emissions generated or released from the manufacturing

process. The industry will provide the efficient scrubbers for controlling the gaseous

emissions and plant will be well ventilated to improve the work zone environment



and layout is worked out in such a way that the workman works in a comfortable

atmosphere by using adequate personal protective equipment. Industry will be taking

all precautions to minimize the emissions on handling of various chemicals etc.

Sufficient fire extinguishers and fire hydrants will be provided in the plant to handle

any emergency.

Full-Fledge ZLD Treatment system will be provided for treating the effluents

generated from the industrial activity. Full-Fledge Treatment facility will be

constructed above ground level to prevent seepage.

First aid kits will be provided in all the departments and training on First aid will also

provide to all the employees for early treatment.

Candidates to be recruited to work in the factory will be subjected to pre employment

medical checkup. Only those certified to be medically fit will be recruited. Candidates

on recruitment safety training will be given for one week on handling of chemicals.

SGR Laboratories Pvt. Ltd. will strictly follow the safety norms as per the guidelines

of the Director of Factories for a process industry and will provide all the necessary

safety equipment for the protection of the Industrial establishment as well as the

personnel working in the plant premises. Personnel Protective Equipment will be

provided to all its employees who are involved in the handling of hazardous

activities. The storage and handling of various chemicals will be according to the

norms of MSDS and the Inspector of Factories. Personnel involved in the production

will be provided with protective clothing, helmets, goggles, masks, gloves, etc.

These handling operations will be carried out under the strict supervision of the

trained and highly skilled personnel. Supervision will be provided to ensure the

usage of these PPE’s. Necessary fire fighting facilities like extinguishers, sand

buckets, etc. will be provided to meet the on-site emergencies. A detailed On-site

Emergency plan will be prepared and implemented comply the provisions of

Factories Act. An agreement with a nearest hospital for treating the employees due

to unforeseen emergencies will be entered into.



10.25 SOCIO-ECONOMIC DEVELOPMENT ACTIVITIES

Socio-Economic Development activities will be implementing in coordination with the

NGOs, Village Panchayats and other Governmental Entities.

A. Social Activities:

Health check up camps and Medical facilities to Infants and senior citizens,

free medicine supply etc., will be provide on regular basis.

Help Implement and Run a Safe Drinking Water in Dondapadu village where

the project site is located to facilitate Healthy Water for both Drinking &

Cooking Purposes.

Contribution towards any development activity useful for village development.

B. Economic Activities:

The company will give preference to the local people for employment.

The company will be giving contract works like civil, machine repair,

transportation, canteen, etc. to the local people / parties.

The proposed project will create jobs for at least 100 persons.

10.26 WASTE MINIMIZATION / RESOURCE CONSERVATION 5 R Concept

(Recycle / Refuse / Reduce / Reuse / Reform)

In our company, the 5R, representing five environment-conscious words starting with

the letter R, has been adopted as a keyword for environmental activities. The five

environment-conscious words include the three R words of the 3R, the keyword for

establishing a recycling-oriented society, and two additional words that are "Refuse"

and "Reform".

Refuse: Avoid purchase of environmentally burdensome materials

whenever possible

Reduce: Reduce waste material

Reuse: Reuse waste material without processing

Reform: Reuse materials in a different form

Recycle: Reuse materials as resources

We will achieve the above concept; all efforts will be made by the industry to carryout

R&D on the isolated by-products / wastes



FIGURE- 10.9: 5 R CONCEPTS

The units shall also implement the waste minimization circle including:

Good House Keeping: Proper housekeeping practices make the system

easier and less costly.

Roof water harvesting system shall be adopted to reduce the fresh water

requirement.

Cleaner production technology may be adopted for the resource conservation

and pollution control.

10.27 CONCLUSION

The industrialization plays an important role in their development process. The

countries with rapidly growing industrial sector were able to manage the

development problems particularly employment, poverty and inequality. The

Industrial development as legitimate objective to solve economic and social

problems, therefore project Management have appropriately decided to setup a

manufacturing unit. The infrastructure like roads, water and regular supply of power

are available at the project site. Availability of adequate skilled, semi-skilled man

power at reasonable salaries and wages, local amenities at reasonable cost, has

encouraged the technocrat. Importantly, the helping hand extended to the most

experienced and reputed person in the bulk drugs manufacturing industrial belt, by

the state Government in meeting the needs of the aspirant.



The likely adverse effects due to the operations of the unit are marginal. More over

the residential area is far away. However, the effective implementation of the

recommended Environment Management Plan and Monitoring Program, by which all

the negative effects on the environment, will be minimized.

SUMMARY & CONCLUSION

[SUMMARY OF EIA REPORT]

CHAPTER -XI


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter -XI Page 347

CHAPTER – XI

PROJECT SUMMARY & CONCLUSIONS

SGR Laboratories Pvt. Ltd. proposed to establish a Bulk Drug & Intermediates

manufacturing unit with the production capacity of 81 TPM respectively.

11.1 SALIENT FEATURES OF THE PROJECT

S.

No Contents Details

1 Name of the Project: SGR Laboratories Pvt. Ltd.

Sy No: 290 & Parts, Dondapadu (V), Chinthalapalem (M), Suryapet District, Telangana.

2 Details of Applicant Mr. A. Koti Reddy (Director) Plot No.108, SVCIE, IDA, Jeedimetla, Hyderabad -500055, Telangana State.

3 Status

SGR Laboratories Pvt. Ltd. proposed to establish

a Bulk Drugs & Intermediates manufacturing unit at

Sy No: 290 & Parts, Dondapadu (V),

Chinthalapalem (M), Suryapet District, Telangana.

4 Type of Land & Status Industrial land.

Proposed Land: 9.0 Acres (36414 Sq. m)

5 Capital Investment of the

Project, Rs. in Crores 12 Crores

6 Capital cost for EMP, Rs. in

Lakhs 110 Lakhs

7 Recurring cost for EMP, Rs.

in Lakhs 15 Lakhs

8 Employment opportunity 100 persons

9 Green belt Development

It is envisaged to develop greenbelt on all sides of

the industry in an area of about 9.00 Acres (36414

Sq. m).

10

Pollution control measures adopted

Effluent water disposal ZLD System

Flue gas emission control

Adequate stacks of height of 30 mts each will be

provided for wider dispersion of pollutants.

For SPM control, provided cyclone separator followed by bag filter

Process gas emission control Two stage scrubbers installed for process gas emissions

Fugitive emission control Vent condensers to the storage tanks and reactors


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter -XI Page 348

S.

No Contents Details

Solvents and chemicals are handling in closed system

Hazardous waste management

All the hazardous waste will be collected, stored, handled, transported and disposed to TSDF as per the Hazardous Waste (Management, Handling and Trans boundary Movement) Rules, 2016, amended time to time etc are major Act/rules/notification applicable to industry.

11 Expenditure for CER & CSR

activities Rs. 54 Lakhs for five years.

11.2 CONCLUSIONS

It can be concluded on a positive note that due to the adequate provision and efficient

operation of Environmental Management Systems and after the implementation of the

proposed mitigation measures and environmental management plans, the project

activities during the construction and operation phase would have manageable & largely

have reversible impacts on the environment, and on balance the project would be

beneficial to surrounding communities and the region.

ENCLOSURES

LAND DOCUMENT

ENCLOSURE - I

LAND CONVERSION

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ENCLOSURE - II

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NABET ACCREDITATION

DETAILS

ENCLOSURE - III

Quality Council of India

QCI National Accreditation Board for Education & Training

· .. · ... . . ....... ·.·.. .

. <Gt!llTIFIC.AIE OF A<GCREDITATIQN ... Rightsource Industrial Solutions Private limited

Plot No.203, H.No.S-36/203, Prashanthi Nagar, IDA Kukatpally Hyderabad- 500072, Telangana

Accredited as Category c A organization under the QCI-NABET Scheme for Accreditation of EIA

Consultant Organizations· Version 3 for preparing EIA-EMP reports in the following Sectors· 51.

Sector Description Sector (as per)

Cat. No. NABET MoE FCC

1 Mining of minerals including opencast I underground mining 1 1 (a) (i) B

2 Pesticides industry and pesticide specific intermediates (excluding

17 5 (b) A formulations)

Synthetic organic chemicals industry (dyes & dye intermediates;

bulk drugs and intermediates excluding drug formulations; 3

synthetic rubbers; basic organic chemicals, other synthetic organic 21 5 (f) A

chemicals and chemical intermediates)

Isolated storage & handling of Hazardous chemicals. (As per

4 threshold planning quantity indicated in column 3 of schedule 2 & 28 6 (b) B 3 of MSIHC Rules 1989 amended 2000)

5 Common Effluent Treatment Plants (CETPs) 36 7 (h) B

6 Building and construction projects 38 8 (a) B Note: Names of approved EIA Coordmators and Functional Area Experts are mf!ntlonf!d m RA AC mmutf!s dated July 20, 2018 posted on QCI-NABET website.

The Accreditation shall remain in force subject to continued compliance to the terms and conditions mentioned in QCI-NABET's letter of accreditation bearing no. QCI/NABET/ENV/AC0/18/0741 dated Sep. 07, 2018. The accreditation needs to be renewed before the expiry date by Rightsource Industrial Solutions Private Limited, Hyderabad, following due process of assessment.

Certificate No. NABET/ EIA/1821/ RA 0100

Valid till 25.02.2021

For the updated list of Accredited EIA Consultant Organizations with approved Sectors please refer to QCI-NABET website.

of sgr laboratories pvt. ltd. labs pvt ltd... · 2019-06-27 · dr. y. rama mohan p. praveen kumar...

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