proposed expansion project for manufacturing of...

PROJECT PRE-FEASIBILITY REPORT

For

Proposed Expansion project For

Manufacturing of synthetic organic chemicals (Bulk Drugs & drug Intermediates)

AT Plot No. C-1/ 7131, 7132, 7133 & C-1/7102

GIDC Estate Ankleshwar, Dist.: Bharuch.

Project Proponent

M/s. Danopharm Chemicals Pvt. Ltd.

i

CONTENTS

CHAPTERS

S. No. Particulars Page No.

1 EXECUTIVE SUMMARY 1-2

2 INTRODUCTION OF THE PROJECT 3-5

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT 3

2.1.1 IDENTIFICATION OF THE PROJECT 3

2.1.2 DETAILS OF PROJECT PROPONENT 3

2.1.3 NATURE OF THE PROJECT 4

2.1.4 NEED OF PROJECT & DEMAND-SUPPLY GAP 4

2.1.5 IMPORTS VS. INDIGENOUS PRODUCTION 5

2.1.6 EXPORT POSSIBILITY 5

2.1.7 DOMESTIC/EXPORT MARKETS 5

3 PROJECT DESCRIPTION 6-20

3.1 TYPE AND LOCATION OF THE PROJECT 6

3.1.1 TYPE 6

3.1.2 LOCATION 6

3.2 DETAILS OF ALTERNATIVE SITE 9

3.3 SIZE & MAGNITUDE OF OPERATION 9

3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS 9

3.5 RAW MATERIAL FOR FINISHED PRODUCT 9

3.6 HAZARDOUS CHEMICALS STORAGE AND HANDLING 11

3.7 RESOURCE OPTIMIZTION & AVAILABILITY 12

3.7.1 LAND & BUILDING REQUIREMENT 12

3.7.2 EQUIPMENT 13

3.7.3 POWER REQUIREMENT 13

3.7.4 FUEL REQUIREMENT 13

3.7.5 WATER REQUIREMENT 13

3.7.6 MAN-POWER REQUIREMENT 14

3.8 QUANTITY OF WASTE TO BE GENERATED 14

3.8.1 WASTE WATER GENERATION & MANAGMENT 15

3.8.2 WASTE WATER CHARACTERISTICS 15

3.8.3 WASTE WATER TREATMENT & DISPOSAL 16

3.8.4 AIR EMISSION & CANTROL 17

3.8.4.1 PROCESS EMISSION 17

3.8.4.2 UTILITY EMISSION 17

3.8.4.3 FUGITIVE EMISSION 18

3.8.5 HAZARDOUS/NON-HAZARDOUS WASTES MANAGEMENT 18

3.8.6 NOISE CONTROL 19

3.9 HEALTH & SAFETY MEASURES 19

3.10 ENVIRONMENTAL HEALTH & SAFETY PLAN 19

3.11 POST PROJECT MONITORING PLAN 20

4 SITE ANALYSIS 21-23

4.1 CONNECTIVITY 21

4.2 LAND FORM, LAND USE & LAND OWNERSHIP 21

4.3 TOPOGRAPHY 21

4.4 SALIENT FEATURES 21

4.5 EXISTING INFRASTRUCTURE 21

4.6 SOIL CLASSIFICATION 21

4.7 CLIMATE & METEROLOGY 22

4.7.1 TEMPERATURE 22

4.7.2 HUMIDITY 23

ii

S. No. Particulars Page No.

4.7.3 RAINFALL 23

4.7.4 CLOUD COVER 23

4.7.5 WIND PATTERN 23

4.8 SOCIAL INFRASTRUCTURE 23

4.9 EDUCATIONAL FACILITIES 23

4.10 MEDICAL FACILITIES 23

5 PLANNING BRIEF 24-25

5.1 PLANNING CONCEPT 24

5.2 POPULATION PROJECTION 24

5.3 AREA STATEMENT 24

5.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

24

5.5 AMENITIES/FACILITIES 24

5.5.1 DRINKING WATER FACILITIES 24

5.5.2 POWER SUPPLY FACILITIES 24

5.5.3 COMMUNICATION & BANKING FACILITIES 24

5.5.4 TRANSPORT FACILITIES 25

6 PROPOSED INFRASTRUCTURE 26-26

6.1 INDUSTRIAL AREA 26

6.2 RESIDENTIAL AREA 26

6.3 GREENBELT 26

6.4 SOCIAL INFRASTRUCTURE 26

6.5 CONNECTIVITY 26

6.6 DRINKING WATER MANAGEMENT 26

6.7 SEWERAGE SYSTEM 26

6.8 INDUSTRIAL WASTE MANAGEMENT 26

6.9 SOLID WASTE MANAGEMENT 26

6.10 POWER REQUIREMENT & SOURCE OF SUPPLY 26

7 REHABILITATION & RESETTLEMENT ( R& R) PLAN 27-27

7.1 POLICY TO BE ADOPTED 27

8 PROJECT SCHEDULE & COST ESTIMATES 28-28

8.1 TIME SCHEDULE OF THE PROJECT 28

8.2 ESTIMATED PROJECT COST 28

9 ANALYSIS OF PROPOSAL 29-29

9.1 FINANCIAL & SOCIAL BENEFITS 29

iii

List of Tables

Table No. Topic Page No.

1.1 PROJECT SUMMARY 1

2.1 LIST OF PRODUCTS 3

2.2 LIST OF DIRECTORS 4

3.1 AREA STATEMENT 8

3.2 LIST OF RAW MATERIALS 9

3.3 DETAILS OF HAZARDOUS CHEMICALS/MATERIALS STORAGE AND HANDLING

11

3.4 LIST OF EQUIPMENT/MACHINERIES 12

3.5 CATEGORY WISE FRESH WATER REQUIREMENT (KL/DAY) 13

3.6 MAN-POWER REQUIREMENT 14

3.7 WASTE WATER GENERATION 14

3.8 STREAM WISE EXPECTED CHARACTERISTICS OF WASTE WATER AFTER PROPOSED EXPANSION

15

3.9 EXPECTED CHARACTERISTICS OF COMPOSITE WASTE WATER 15

3.10 DETAILS OF EACH ETP UNIT 17

3.11 DETAILS OF PROCESS EMISSIONS 17

3.12 DETAILS OF UTILITY EMISSIONS 17

3.13 HAZARDOUS AND NON-HAZARDOUS WASTE GENERATION AND ITS MANAGEMENT

18

3.14 SAFETY DETAILS 19

3.15 ENVIRONMENTAL MONITORING PLAN 20

4.1 SALIENT FEATURES OF THE PROJECT SITE 21

4.2 SUMMARY METEOROLOGICAL DATA AT NEAREST IMD STATION- BHARUCH

22

5.1 DISTRIBUTION OF POPULATION 24

8.1 TOTAL CAPITAL COST PROJECTION 28

List of Figures

Sr. No. Description Page No.

3.1 LOCATION OF THE PROJECT SITE 6

3.2 SATELLITE IMAGE OF THE PROJECT SITE 7

3.3 SITE LAYOUT PLAN 8

3.4 WATER BALANCE DIAGRAM (IN KL/DAY) FOR EXISTING SCENARIO 14

3.5 WATER BALANCE DIAGRAM (IN KL/DAY) FOR PROPOSED SCENARIO 15

3.6 FLOW DIAGRAM OF ETP 16

3.7 ORGANOGRAM OF EHS CELL 19

List of Annexures

Sr. No. Description

Annexure 1 Existing CC&A

Annexure 2 Process technology

Annexure 3 Land Possession Documents

Annexure 4 CETP Membership certificate

Annexure-5 BEIL Membership certificate

Project Pre-feasibility report

Proposed Expansion project for manufacturing of synthetic organic chemicals Page | 1

CHAPTER – 1

EXECUTIVE SUMMARY The project is summarized in the below table:

Table1.1: Project Summary

PARTICULARS DETAILS NAME OF THE UNIT M/s. Danopharm Chemicals Pvt. Ltd. OCCUPIER Mr. Jayanta Das PRODUCTS The list of products are as follows:

Sr. No.

Products Total Quantity (T/month) Existing After proposed expansion

Existing products1. 2 Amino 5 Nitro

Benzophenone 1.5 3

2. Ofloxacin

9.0

---3. Levofloxacin ---4. Ciprofloxacin ---5 Norfloxacin 156. Ernofloxacin ---Proposed products7. Celecoxib --- 38. CIS Tosylate --- 59. 4- Chloro Phenyl

Hydrazine Hydrochloride --- 10

10. 4,4,4, - Trifluro - 1 - (4-methylphenyl) - Butane - 1.3 – Dione

--- 5

11. Ketoconazole --- 512. Metronidazole Benzoate --- 1513. 4- Sulphonamido Phenyl

Hydrazine Hydrochloride --- 10

14. Carboxy Diphenyl Amine --- 2TOTAL 10.5 73

LOCATION Plot No. C-1/ 7131, 7132, 7133 & C-1/7102 GIDC Estate Ankleshwar, Dist.: Bharuch.

NAME OF PROJECT

Proposed expansion project for manufacturing of synthetic organic chemicals (Bulk drugs & drug intermediates)

RESOURCES Resource type Requirement SourceLand Existing land: 2915.80 m2

No additional land will be required for proposed expansion. Necessary modifications will be done in the existing infrastructure.

The existing site is located in GIDC estate, Ankleshwar.

Water Existing: Total 9.8 kl/day Domestic: 1.0 kl/day Industrial: 8.8 kl/day Gardening: 0.10 kl/day After proposed expansion: Total 75.00 kl/day Domestic: 4.50 kl/day Industrial: 69.00 kl/day Gardening: 1.50 kl/day

The fresh water is/will be supplied by GIDC water supply department.



PARTICULARS DETAILS Power Existing: 250 kVA

After proposed expansion: 700 kVA The power supply is/will be supplied by Dakshin Gujarat Vij Co. Ltd.

Fuel Existing: Natural gas: 1200 SCM/day After proposed expansion: Natural gas: 3000 SCM/day

Natural gas is/will be sourced from Gujarat Gas Ltd.

POLLUTION POTENTIAL & MITIGATION MEASURESParameter Potential Mitigation Wastewater Existing:

Total 5.30 kl/day Domestic: 0.7 kl/day Industrial: 4.60 kl/day After proposed expansion: Total 48.50 kl/day Domestic: 3.50 kl/day Industrial: 45.00 kl/day

Domestic waste water is/will be disposed through septic tank/ soak pit system.

The industrial effluent after conforming the standards prescribed by GPCB is/will be discharged through underground GIDC drainage and finally conveyed to M/s. NCTL which ultimately leads to deep sea for final disposal.

Air Emissions Existing: Boilers: Capacity 850 kg/hr x 1 no.

and capacity 600 kg/hr x 1 no. After proposed expansion: Boiler: Capacity 1.5 TPH x 1 no. Thermic fluid heater: Capacity 4

lakh kCal/hr x 1 no.

After the proposed expansion project, existing 2 nos. of boilers having capacity 850 kg/hr and 650 kg/hr will be as stand-by after the installation of boiler having capacity 1.5 TPH.

Hazardous & solid waste

Existing: Residue wastes (Cat. 28.1): 0.015 T/annum Spent carbon (Cat. 28.2): 0.015 T/annum Used oil (Cat. 5.1): 0.017 T/annum Discarded drums/liners (Cat. 33.3): 50 T/annum ETP sludge (Cat. 34.3): 8.9 T/annum After proposed expansion: Residue wastes (Cat. 28.1): 11 T/annum Spent carbon + Hyflow (Cat. 28.2): 1.10 T/annum Used oil (Cat. 5.1): 0.10 T/annum Discarded drums/liners (Cat. 33.3): 2070 T/annum ETP sludge (Cat. 34.3): 60 T/annum

ETP sludge is/will be disposed to TSDF site, BEIL, Ankleshwar.

Residue waste, spent carbon and hyflow is/will be disposed to incineration site.

Used oil is/will be disposed by selling to registered refiners.

Discarded drums/liners is will be reuse/disposed by selling to GPCB authorized vendor after de-contamination/re-used.

Noise Expected levelsWithin the premises During day time <75 dB(A) Durig night time <70 dB(A)

Major noise generation is/will be from pumps, motors and D.G. sets.

Acoustic enclosure will be provided to D.G. sets.

Ear Plugs and Ear muffs provided to the workers in Utility Section.



CHAPTER – 2

INTRODUCTION OF THE PROJECT

2.1 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT

2.1.1 IDENTIFICATION OF THE PROJECT

M/s. Danopharm Chemicals Pvt. Ltd. is located at plot no. C-1/ 7131, 7132, 7133 & C-1/7102 GIDC Estate Ankleshwar, Dist.: Bharuch, Gujarat – 393 002.

The unit has obtained CC&A for its existing plant vide CC&A No.: AWH-66653 dated 03/12/2014 and valid up to 02/05/2019. The copy of existing CC&A is attached as Annexure-1.The list of products are as follows:

Table-2.1: List of products

Sr. No.

Products Total Quantity (T/month) Existing After proposed expansion

Existing products 1. 2 Amino 5 Nitro Benzophenone 1.5 3 2. Ofloxacine

9.0

--- 3. Levofloxacin --- 4. Ciprofloxacin --- 5 Norfloxacin 15 6. Ernofloxacin --- Proposed products 7. Celecoxib --- 3 8. CIS Tosylate --- 5 9. 4- Chloro Phenyl Hydrazine Hydrochloride --- 10 10. 4,4,4, - Trifluro - 1 - (4-methylphenyl) - Butane -

1.3 - Dione --- 5

11. Ketoconazole --- 5 12. Metronidazole Benzoate --- 15 13. 4- Sulphonamido Phenyl Hydrazine Hydrochloride --- 10 14. Carboxy Diphenyl Amine --- 2 TOTAL 10.5 73

(Source: Danopharm Chemicals Pvt. Ltd., Ankleshwar)

2.1.2 DETAILS OF PROJECT PROPONENT

M/s. Danopharm Chemicals Pvt. Ltd. was established in 1986, and is engaged in the manufacturing of bulk drugs and intermediates. M/s. Danopharm Chemicals Pvt. Ltd. has a broad based well-knit professionally managed organization set up with departments headed by exceptionally competent persons. The main complexes for production, research & development and quality assurance are located at G.I.D.C., Ankleshwar, and District. Bharuch. The company has its head office in Mumbai from where it does its marketing of its products locally and internationally.

The plant is well equipped with a full-fledged Research and Development and Quality Control Laboratory. The plant is involved in the state of the art technologies for Hi-tech products.

M/s. Danopharm Chemicals Pvt. Ltd. is backed by a team of dedicated hard working staff having wide experience in the manufacturing and marketing of pharmaceutical products. This enables M/s. Danopharm Chemicals Pvt. Ltd. to grow and continue to fulfill traditional objectives of:

Established high standards of quality by thorough adherence to good manufacturing practices.



Producing effective products of consistent quality available at the most competitive price.

The company is backed by strong Quality Control department, which take care of all stringent international standard conditions. The QC department’s main objective is to maintain a very strong control on the quality for:

Raw material (input) prior to production.

In process Quality Control

Finished Drug & Intermediates.

It is in the company tradition to send finished products randomly selected from any batch, to accredited laboratories for testing. This provides corroborative assurance that the product of M/s. Danopharm Chemicals Pvt. Ltd. conform to the highest international standards. Research and Development is a full time activity of M/s. Danopharm Chemicals Pvt. Ltd.

A strong quality consciousness and uncompromising attitude within M/s. Danopharm Chemicals Pvt. Ltd. has helped the company establish a very strong clientele base in India and abroad.

M/s. Danopharm Chemicals Pvt. Ltd. is a steady growing company since its incorporation in 1986, in the field of Chemicals. The directors of the company have good experience in handling the production management, financial management and all the allied areas. The detailed list of partners is as under:

Table 2.2: List of Directors

Sr. No. Name of the Directors Address

1 Mr. Satish P. Nachane 1801, Ixora Tower, Hiranandani Meadows, Off. Pokharan Raod No.2, Thane (W)-400610.

2 Mr. Jayanta B. Das G-105 & 106, Palm Project, D-mart, Link Road, Malad (W) Mumbai-400064.

3 Mr. Mehul S. Nachane 1801, Ixora Tower, Hiranandani Meadows, Off. Pokharan Raod No.2, Thane (W)-400610.

4 Mr. Kashi B. Das 102, Sai Trishul, Raviraj Complex, off new Link road, Andheri (W) Mumbai-400053.

5 Mr. Kamlesh B. Das G-1105 & 1106, Palm Project, D-mart, Link Road, Malad (W) Mumbai-400064.

6 Mr. Bimlesh B. Das Flat No.502, Skydeck Co-op Housing Society, off new link road, Andheri (W) Mumbai-400053.

7 Mr. Ramesh Jadhav Anand Regency, Flat No.501-B-Wing, Near Jain Society, Kalatalab, Kalyan (W)-421301

8 Mr. Sabu Daniel 501,E Buldg, New Brahman Complex, Azad Nagar, Thane(W)-400607


2.1.3 NATURE OF THE PROJECT

The proposed expansion project is for manufacturing of synthetic organic chemicals (Bulk drugs and drug intermediates) which is categorized as ‘Category B’ and falls under item no. “5 (f) i.e. Synthetic Organic Chemicals” as per EIA Notification, 2006 (amended from time to time). Due to the applicability of general conditions i.e. located within 5 km distance from Critically Polluted area (Ankleshwar), the proposed expansion project is categorized as ‘category A“ and needs to obtain environmental clearance from MoEF&CC.

2.1.4 NEED OF PROJECT & DEMAND-SUPPLY GAP

Danopharm Chemicals Pvt. Ltd. is a pharmaceutical company, engaged in the manufacture of bulk drugs and intermediates. Being a growing company, it expands to diversify product range and increase



market share in domestic and export market. Adoption of the latest technology is a part and parcel of this process.

To stay relevant in the pharmaceutical sector, we need to grow, bring in more drugs, more intermediates in our basket and also increase export to foreign countries. The demand for anti-inflammatory and anti-microbial drugs are increasing worldwide. In addition to these drugs, we plan to enter ant-Fungal segment. This will not only helps us to grow financially, but also earn foreign exchange and generate local employment, thus fulfilling our social obligation.

2.1.5 IMPORTS VS. INDIGENOUS PRODUCTION

It is in the company policy to procure indigenously produced raw materials. Only when a particular raw material is not available locally, we Import it.

2.1.6 EXPORT POSSIBILITY

The products are highly influenced by the market demand and market rates of the products and raw materials. Though the company has strong Indian base, all the products are developed keeping the global market into consideration. By virtue of its own infrastructure facility, skilled manpower, and large production capacity, M/s. Danopharm Chemicals Pvt. Ltd. can offer products of international standards at most competitive price on time.

2.1.7 DOMESTIC / EXPORT MARKETS

We cater both domestic and international market. Just two years back our exports was only 2% and today our export is about 54% of our turnover. We are targeting to achieve 70% export in next two years.



CHAPTER – 3

PROJECT DESCRIPTION 3.1 TYPE & LOCATION OF THE PROJECT 3.1.1 TYPE

The proposed expansion is to be carried out in the existing site itself, so that the existing infrastructure and resources can be utilized for the proposed expansion.

3.1.1.1 LOCATION

The project site is located in the GIDC notified industrial area of Ankleshwar. This region has very good infrastructure facility. The resources are also readily available. Moreover, there is availability of Common Solid Waste Disposal (CSWD) facilities and the Disaster Prevention & Management Centre (DPMC) is located in the GIDC industrial estate.

The location of the project site is provided in figure 3.1, satellite image of the project site is provided in figure 3.2 and the site layout plan of the project site in figure 3.3. The area statement is provided in table 3.1.

Figure 3.1: Location of the project site

(Source: Google)



Figure 3.1: Satellite image of the project site

(Source: Google Earth)



Figure 3.3: Site layout plan

(Source: Danopharm Chemicals Pvt. Ltd., Ankleshwar

Table: 3.1 Area Statement

Sr. No. Description Area (m2)1. Total built-up area 997.412. Greenbelt area 969.523. Open area 589.014. Proposed area 330.55

TOTAL 2915.80(Source: Danopharm Chemicals Pvt. Ltd., Ankleshwar)



3.2 DETAILS OF THE ALTERNATIVE SITE

The proposed expansion will be carried out on the existing site located in the notified industrial estate of Ankleshwar. Due to the availability of necessary resources, the company has not proposed any alternative site for proposed expansion.

3.3 SIZE & MAGNITUDE OF OPERATION

Total production after the proposed expansion will be 73 T/month.

3.4 PROJECT DESCRIPTION WITH PROCESS DETAILS

The details of process technology is provided in Annexure-2.

3.5 RAW MATERIAL FOR FINISHED PRODUCTS

The list of raw-materials required are as follows:

Table 3.2: List of raw materials

Sr. No.

Product Raw material Requirementkg/kg kg/day

Existing products 1. 2 Amino 5

Nitro Benzophenone

2-Chloro 5-Nitro Benzophenone 64.00 1920.00Liquid Ammonia 108.00 3240.00Acetic Acid 6.00 180.00

2. Ofloxacin Methanol 696.43 20892.86O.Q. Acid 300.00 9000.00N-Methyl Piperazine 96.43 2892.86Caustic Flakes 42.86 1285.71HCl 21.43 642.86

3. Levofloxacin Metanol 696.43 20892.86O.Q.Acid 300.00 9000.00N-Methyl Piperazine 96.43 2892.86Caustic Flakes 42.86 1285.71HCl 21.43 642.86

4. Ciprofloxacin Metanol 696.43 20892.86O.Q.Acid 300.00 9000.00Anhydrous Piperazine 96.43 2892.86Caustic Flakes 42.86 1285.71HCl 21.43 642.86

5 Norfloxacin Methanol 696.43 20892.86O.Q.Acid 300.00 9000.00Anhydrous Piperazine 96.43 2892.86Caustic Flakes 42.86 1285.71HCl 21.43 642.86

6 Enrofloxacin Methanol 696.43 20892.86Enro.Q. Acid 300.00 9000.00N-Ethyl Piperazine 96.43 2892.86Caustic Flakes 42.86 1285.71HCl 21.43 642.86

Proposed products 7 2 Amino 5

Nitro Benzophenone

2-Chloro 5-Nitro Benzophenone 160.00 106.66Liquid Ammonia 270.00 180.00Acetic Acid 10.00 300.00

8 Celecoxib SPHHCL 100.00 68.96Dione 104.00 71.72Toluene 2871.00 1980.00



Sr. No.


Carbon 8.00 5.529 Cis Tosylate Cis Bromo Benzoate (CBB) 555.00 193.92

Imidazole 509.00 177.88DMF 31.00 10.83Toluene 2183.00 762.75Caustic 41.00 14.33MDC 1316.25 459.91Para Toluene Sulphonyl Chloride(PTSC) 228.00 79.66Triethyl Amine (TEA) 106.00 37.03Liq. Ammonia 27.00 9.43Ethyl Acetate 425.00 148.49

10 4- Chloro Phenyl Hydrazine Hydrochloride

HCl 664.00 1383.33Para Chloro Aniline (PCA) 125.00 260.42Sodium Nitrite 76.50 159.37Sodium Bisulphide 5.00 10.42Soda Ash 94.00 195.83Caustic 200.00 416.66NaCl 20.00 41.66

11. Ketoconazole DMSO 200.00 166.661-Acetyl-4-(4-hydroxy Phenyl) Piperazine (AHPP) 90.00 75.00SMO 24.00 20.00CTS 200.00 166.66Acetone 200.00 166.66Hyflow 2.00 1.66Ethyl Acetate 1092.00 910.00Methanol 312.00 260.00Carbon 12.00 10.00

12. Metronidazole Benzoate

Metronidazole 825.00 343.75Beta Picoline 515.00 214.58Soda Ash 11.00 4.58Benzoyl Chloride 680.00 283.33Sodium Bicarbonate 11.00 4.58Methanol 1440.00 600.00Carbon 4.00 1.66Hyflow 2.00 0.83Caustic flakes 25.00 10.42

13 4- Sulphonamido Phenyl Hydrazine Hydrochloride

HCl 806.00 1414.04Sulphanilamide 160.00 280.70Sodium Nitrite 64.80 113.68Sodium Bisulphide 4.00 7.02Soda Ash 88.00 154.38Carbon 3.00 5.26Hyflow 1.00 1.75

14. Carboxy Diphenyl Amine

Ethanol Denatured Toluene 1190.00 223.47Diethyl Malonate 189.00 35.49KOH 72.00 13.52Washing (Ethanol Denatured Toluene) 132.00 24.78Chloro Nitro Diphenyl Amine 248.00 46.571-Chloro Butane 1200.00 225.35PCl 5 98.00 18.40Sodium Bicarbonate solution 105.00 19.72Carbon 5.00 0.94Mix Xylene 65.00 12.21N-Hexane 50.00 9.38



Sr. No.


15 Norfloxacin Methanol 1625.00 9027.78Nor Acid 625.00 3472.22Anhydrous Piperazine 225.00 1250.00Caustic Flakes 50.00 277.77HCl 50.00 277.77

16. 4,4,4, - Trifluro - 1 - (4-methylphenyl) - Butane - 1.3 - Dione

Trifluroacetic Acid 146.00 105.79Sulphuric acid 11.00 7.97Iso Propyl Alcohol 114.00 82.61Toluene 1050.00 760.87SMO 70.00 50.72MAP 139.00 100.72HCl 276.00 200.00


3.6 HAZARDOUS CHEMICAL STORAGE & HANDLING

The list of hazardous chemicals/materials storage, handling and transportation details are as follows:

Table 3.3: Details of hazardous chemicals/materials storage and handling

Sr. No.

Raw Material Source Means of storage

Means of transport

Storage conditions

Max. Qty. to be stored (T)

Press. kg/m2

Temp (ºC)

1 1-Chloro Butane Local Drums-100 kg Truck AP RT 0.1002 2-Chloro 5-Nitro

Benzophenone Local

Bags-40 kg Truck AP RT 0.640

3 Acetic Acid Local Drums-200 kg Truck AP RT 2.5004 Acetone Local Drums-160 kg Truck AP RT 2.2405 Activated Carbon Local Bags-30 kg Truck AP RT 0.3006 AHPP Local Drums-25 kg Truck AP RT 1.0007

Benzoyl Chloride Local/Import

Drums-240 kg Truck

AP RT 10.000

8 Beta Picoline

Local/Import

Drums-200 kg Truck

AP RT 6.000

9 Caustic Flakes Local Bags-50 kg Truck AP RT 10.00010 CBB Local Drums-50 kg Truck AP RT 1.20011 DMF Local Drums-190 kg Truck AP RT 0.38012 DMSO Local Drums-225 kg Truck AP RT 3.00013 Ethyl Acetate Local Drum-210 kg Truck AP RT 5.00014 HCl Local Bulk -10000 kg Tanker AP RT 10.00015 Hyflow Local Bags-25 kg Truck AP RT 0.20016

Imidazole Local/Import

Drums-100 kg & 25 kg. Truck

AP RT 5.000

17 Iso Propyl Alcohol Local Drums-160 kg Truck AP RT 9.00018 Liq. Ammonia Local Drums-200 kg Truck AP RT 1.40019

4-MAP Local/Import

Drums-200 kg Truck

AP RT 4.000

20 MDC Local Drums-250 kg Truck AP RT 3.00021 Methanol Local Bulk-9200 kg Tanker AP RT 9.20022

Metronidazole Local/Import

Drums-25 kg Truck

AP RT 13.000

23 N-Methyl Piperazine

Local/Import

Drums-180 kg Truck

AP RT 4.000



Sr. No.

Raw Material Source Means of storage

Means of transport

Storage conditions

Max. Qty. to be stored (T)

Press. kg/m2

Temp (ºC)

24 O.Q. Acid

Local/Import

Drums-25 kg Truck

AP RT 4.000

25 PCA Local Bags-50 kg Truck AP RT 3.00026 PTSC Local Drums-50 kg Truck AP RT 1.00027

SMO Local/Import

Drums-110 kg Truck

AP RT 4.400

28 Soda Ash Local Bags-50 kg Truck AP RT 4.00029 Sodium

Bicarbonate Local

Bags-50 kg Truck

AP RT 0.600

30 Sodium Bisulphide Local Bags-50 kg Truck AP RT 6.00031 Sodium Nitrite Local Bags-50 kg Truck AP RT 4.00032 Sulphanilamide Local Bags-40 kg Truck AP RT 10.00033 Sulphuric Acid Local Carboys-40 kg Truck AP RT 0.48034 TEA Local Drums-140 kg Truck AP RT 1.50035 Toluene Local Drums-180 kg Truck AP RT 3.00036

Trifluroacetic Acid Local/Import

Drums-250 kg Truck

AP RT 3.000


3.7 RESOURCE OPTIMIZATION & AVAILABILITY

The main resources for the proposed expansion project will be machineries, raw-materials, power, fuel, water, man-power etc.

3.7.1 LAND & BUILDING REQUIREMENT

The existing land is 2915.80 m2. No additional land will be required for the proposed expansion. Necessary modifications will be done in the existing plant. The plot allotment letter is attached herewith as Annexure-3.

3.7.2 EQUIPMENT

The list of equipments required for the proposed expansion project are as follows:

Table 3.4: List of equipment/machineries

Sr. No. Equipments/Machineries Quantity (Nos.)A SS Reactors

1) 3 kl 22) 4 kl 13) 5 kl 2

B GL Reactor 1) 3 kl 22) 5 kl 2

C SS Centrifuge 1) 48” 22) 36” 2

D RL Centrifuges 1) 48” 2

E Dryer 1) ANFD 2

F Boiler 1) Thermic fluid heater 1




3.7.3 POWER REQUIREMENT

The existing power requirement is 250 kVA. It is sourced from Dakshin Gujarat Vij Company Limited. (DGVCL). For the proposed expansion project, the power requirement will be increase to 700 kVA. It will also be sourced from DGVCL.

3.7.4 FUEL REQUIREMENT

For existing operations, natural gas @1200 SCM/day is used as fuel in boilers. After the proposed expansion, natural gas @3000 SCM/day will be used as fuel. Natural gas is/will be sourced from Gujarat Gas Ltd.

3.7.5 WATER REQUIREMENT

Fresh water requirement after the proposed expansion will be @75 kl/day. The fresh water is/will be sourced from GIDC water supply department.

Other than general requirement of water in domestic and utilities, it will also be required in process. The category wise bifurcation of fresh water is given as follows:

Table 3.5: Category wise fresh water requirement

Particulars Existing operation (kl/day) After proposed expansion (kl/day)Domestic 0.90 4.50Gardening 0.10 1.50Industrial Process 3.00 21.50Boiler 1.50 7.50Cooling tower 4.00 31.00Washing 0.10 4.50Scrubber 0.20 4.50Sub: Industrial 8.80 69.00Total 9.80 75.00


3.7.6 MAN-POWER REQUIREMENT

In existing operations, the man-power requirement is 28 persons and after the proposed expansion project it will be 85 persons. The man-power will be employed locally. The bifurcation of man-power is given as below:

Table 3.6: Man-power requirement

Phase of project Type of labour No. of workers (Existing)

No. of workers(Proposed)

During construction Contractual ----- ----- During commissioning Contractual ----- ----- During operations Managerial 5 10

Skilled 8 15 Un-skilled 15 60




3.8 QUANTITY OF WASTE TO BE GENERATED

The quantity wise bifurcation of waste water is provided below table.

Table 3.7: Waste water generation

Particulars Existing operation (kl/day) After proposed expansion (kl/day)Domestic 0.8 3.50Industrial Process 3.25 26.50Boiler blow down 0.75 3.50Cooling tower blow down 0.50 6.00Washing 0.10 4.50Scrubber 0.20 4.50Sub-total: Industrial 4.60 45.00TOTAL 5.40 48.50

(Source: Danopharm Chemicals Pvt. Ltd., Ankleshwar) The water balance diagram for existing scenario is provided in figure 3.4 and for proposed scenario is provided is provided in figure 3.5.

Figure 3.4: Water balance diagram for existing scenario




Figure 3.4: Water balance diagram for proposed scenario


3.8.1 WASTE WATER GENERATION & MANAGEMENT

The domestic waste water generated is/will be disposed to septic tank system.

3.8.2 WASTE WATER CHARACTERISTICS

The expected characteristics of composite waste water are as follows:

Table 3.8: Stream wise characteristics of waste water

Sr. No.

Effluent Stream

Expected CharacteristicspH TDS COD BOD

1. Process 6.0-9.0 13000-16000 7000-10000 2100-30002. Cooling Tower Blow down 6.0-9.0 1200-1500 100-200 30-603. Boiler blowdown 6.0-9.0 1200-1500 100-200 30-604. Washing 6.0-9.0 1000-1200 1500-2000 450-6005. Scrubber 6.0-9.0 1800-2300 2000-2500 600-750Note: All units are in mg/l except pH.


Table 3.9: Expected characteristics of composite waste water

Sr. No.

Parameters Expected Characteristics NCTL Discharge NormsExisting –

UntreatedProposed –

Untreated1. pH 6.0-9.0 6.0-9.0 6.0-9.02. Total dissolved solids (TDS) 8000-10000 10000-12000 No limit3. COD 2500-3500 4500-5500 5004. BOD 450-600 1300-1600 100Note: All units are in mg/l except pH.




3.8.3 WASTE WATER TREATMENT & DISPOSAL

Domestic waste water is/will be disposed through septic tank system. The overflow from septic tank is/will be diverted to aeration tank for further treatment.

In existing operations, the waste water from process, plant washing etc. is diverted to ETP consisting of primary, secondary and tertiary treatment. The treated effluent is discharged through underground GIDC drainage after meeting the prescribed norms given by FETP (Final effluent treatment plant). The membership certificate of FETP is attached herewith as Annexure-4.

After the proposed expansion project, necessary modifications will be done in the existing ETP for the treatment of waste water. The flow diagram of ETP is provided in figure 3.6 and the details of each unit is given in table 3.9.

Figure 3.6: Flow diagram of ETP




Table 3.10: Details of ETP units

Sr. No. Description Capacity1. Collection Tank 12 m3

2. Neutralization tank 123. Primary settling tank 7.84. Aeration tank 2665. Secondary settling tank 7.86. Clarified water tank 5.27. Pressure sand filter -----8. Activated carbon filter -----9. Sludge drying beds 410. Sludge storage area -----


3.8.4 AIR EMISSIONS & CONTROL

The details of air emissions are given as follows:

3.8.4.1 PROCESS EMISSION

In existing operations, the process emissions is in form of HF, HCl and SO2 gas which is scrubbed using two stage scrubber with water and caustic soda solution. The concentrated solution from scrubber is diverted to ETP for further treatment.

After the proposed expansion, the same process will be done to control process emissions.

The details of process emissions are provided in table 3.10.

Table 3.11: Details of process emissions

Sr. No.

Vent attached to

Probable Pollutant émissions

Air Pollution Control Device (APCD)

Height & Diameter of the Vent (m)

Permissible limit

Existing 1. Reaction

vessel HF

Two stage water and Caustic scrubber

H:12 m Dia.: 0.5 m

4 mg/Nm3

HCl 20 mg/N m3

SO2 40 mg/N m3

Proposed additional No additional vent will be required for the proposed expansion


3.8.4.2 UTILITY EMISSION

In existing operations, the company has already installed 2 nos. of boilers having capacities 850 kg/hr and 600 kg/hr each. Natural gas@95 m3/hr is used as fuel in boilers. After the proposed expansion, the company will install one boiler having 1.5 TPH capacity. Existing boilers will be used as stand-by arrangement.

The details of utility emissions are provided in table 3.11.

Table 3.12: Details of utility emissions

Installation Fuel Fuel Consumption

Details of stack

Pollution Parameters

Emission

Rate

Air Pollution Control System

Existing installations NON IBR Boiler (850 Kg/Hr)

Natural gas

55 m3/hr Common stack

SPM 150 mg/Nm3 ----- SO2 100 ppm

NO2 50 ppm



Installation Fuel Fuel Consumption

Details of stack

Pollution Parameters

Emission

Rate

Air Pollution Control System

NON IBR Boiler (600 Kg/Hr)

Natural gas

40 m3/hr Height (H): 12 m Diameter (D): 0.1 m

SPM 150 mg/Nm3 SO2 100 ppm NO2 50 ppm

Proposed additional installationsThermic fluid heater 4 lakh k.Cal/hr. 1 no.

Natural gas


SPM 150 mg/Nm3

-----

SO2 100 ppm NO2 50 ppm

IBR Boiler (1.5 TPH)

Natural gas


SPM 150 mg/Nm3 SO2 100 ppm NO2 50 ppm

Note: Existing boilers will be replaced by proposed additional boiler having capacity 1 TPH(Source: Danopharm Chemicals Pvt. Ltd., Ankleshwar)

3.8.4.3 FUGITIVE EMISSION

The fugitive emissions in terms of handling losses of solvent is/will be reduced by proper storage and handling. Solvents is/will be stored in drums in the solvent storage area. They is/ will be transferred to the plant by trolleys. Acids is/will be stored in carboys and the storage area is/ will be provided with acid proof lining. Other RM and Finished goods is/will be stored in their designated areas.

3.8.5 HAZARDOUS/NON-HAZARDOUS. WASTES MANAGEMENT

Hazardous and non-hazardous is/will be generated from the proposed project. All such types of wastes is/will be stored in the proper designated storage areas. The details of hazardous and non-hazardous waste generation and its management are provide in table 3.12. Membership certificate from BEIL, Ankleshwar is attached as Annexure-5.

Table 3.13: Hazardous and non-hazardous waste generation and its management

Sr. No.

Type of waste

Category Quantity Mode of disposal Existing After proposed

expansion 1. Residue

waste 28.1 0.015

T/annum 11 T/annum Collection, storage,

transportation and disposal by incineration.

2. Spent Carbon & Hyflow

28.2 0.015 T/annum

1.10 T/annum Collection, storage, transportation and disposal by incineration

3. Used Oil 5.1 0.017 T/annum

0.020 T/annum Collection, storage, transportation disposal by selling to Registered re-cyclers

4. Discarded drums/ liners

33.3 50 T/annum

2070 T/annum Collection, storage, transportation and disposal by sale it to GPCB authorized vendor after decontamination/ re-used.

5. ETP sludge

34.3 8.9 T/annum

60 T/annum Collection, storage, transportation disposal at common TSDF BElL.




3.8.6 NOISE CONTROL

The major noise generating installation will be the D.G. Set. It will be installed in a closed room. Acoustic enclosure will be provided around it and ear plugs will also be provided to the operating personnel. Sturdy foundation and suspension will be provided to centrifuge.

3.9 HEALTH AND SAFETY MEASURES

The details of safety measures provided and safety procedure followed at our unit are as below:

Table 3.14: Safety details

Sr. No. Particulars Remarks/ Details1. Safety Officer Safety officer is available 2. Manual call bells Yes 3. Emergency Control Room At main gate security office 4. Emergency Sirens Yes 5. Assembly Point 1 point 6. Ambulance Point Near main gate 7. First Aid facility Provided at prominent places by trained persons. 8. Personal Protective

Equipments Hand gloves, gum boots, safety shoes, dust masks, safety goggles, and apron.

9. Health Check ups Regular health checkup at every six months. 10. Regular Training Provided 11. Safety & Health Records Maintained as per factory act 12. MSDS MSDS available at prominent places for ready references

(Source: Danopharm chemicals Pvt. Ltd., Ankleshwar)

3.10 ENVIRONMENTAL HEALTH & SAFETY PLAN

The company will appoint separate cell setup to keep a close watch on the performance of the pollution control equipments, emissions from the sources and the quality of surrounding environment in accordance with the monitoring program. The cell will also include the safety cell for observing, inspecting and regulating the safety measures inside the plant campus. The cell will be responsible for maintaining records of all the data, documents and information in line with the statutory requirements. Organogram of the E.H.S Management Cell will be as under:

Figure 3.7: Organogram of EHS management cell




3.11 POST PROJECT MONITORING PLAN

The proposed post-project monitoring plan to ensure effective implementation of EHS Management system is given below:

Table 3.15: Environmental Monitoring Plan

Component Parameter Frequency Air – Ambient SPM, RSPM, SO2, NO2 Quarterly Process Stack monitoring

HCl, SO2 Quarterly

Noise monitoring Noise levels in decibels Quarterly at all noise generating equipments & plant boundary

Work place monitoring

VOC, HF, HCl, SO2 Quarterly

Haz. Waste management

Maintaining records of generation, receipt & disposal in Form-3

Yearly

Filing of annual returns in Form-4 for Haz. Waste handling

Yearly

CC&A Obtaining consent to operate (and renewal) under Air & Water Acts and authorization under HW rules.

Before expiry of validity

Water cess Filing of annual returns for cess incurred on water consumption

Yearly

Environmental Statement

Submission of audit statement in form-V Yearly

Compliance of EC conditions

Submission of compliance reports Half yearly on 1st June & 1st Dec




CHAPTER – 4

SITE ANALYSIS

4.1 CONNECTIVITY

This proposed expansion project is located at Plot No. C/1- 7131, 7132, 7133 & 7102 GIDC Estate, Ankleshwar, Dist.: Bharuch, Gujarat – 393 002. The site is 3.20 km from National highway. The land and infrastructure is already available. And the raw material is easily available through the easy transport via road connectivity. The nearest Railway station is Ankleshwar railway station which is 4.20 km and Surat Airport is 61.59 km from the project site.

4.2 LANDFORM, LAND USE & LAND OWNERSHIP

The existing land is about 2112 m2. Additional 704 m2 of land will be required for the proposed expansion. The existing plot is located in the industrial estate of GIDC, Ankleshwar designated for the industrial purpose. Hence, there will be no change in the land-use pattern of the area.

4.3 TOPOGRAPHY

The topography of the Ankleshwar is relatively flat terrain with series of deeply incised creeks of river. There are generally levee deposits on the bank of river.

4.4 SALIENT FEATURES

The salient features of the project site is provided in table 4.1.

Table 4.1: Salient Features of the Project Site

Particulars DetailsApprox. site Co-ordinates Latitude:21°61’69.19” , Longitude:73°04’15.87” Village/Town Ankleshwar Taluka/ Tehsil Ankleshwar District Bharuch Nearest Water body River Narmada ≈ 8.58 km (NW) Gulf of Cambay ≈ 47 km

(W) Nearest Highway NH 8 ≈ 3.40 km (N) Nearest Railway station & Railway line Ankleshwar Railway Station ≈ 4.20 (W) Nearest Airport/ Airbase Surat ≈ 61.59 km (SW) State/ National borders Daman ≈ 138.20 km (S) Protected Area/ Sanctuaries No CRZ applicability No Seismicity Seismic Zone – III (Moderate) Note: All the above mentioned distances are the aerial distance from the project site.

4.5 EXISTING INFRASTRUCTURE

The proposed expansion will be done in the existing land. Necessary modifications will be done in the existing infrastructure.

4.6 SOIL CLASSIFICATION

The soil type in the area of Ankleshwar is deep black clayey soils. Most of the area cultivated, some area are non- cultivated under fallow and pasture forest. The surface colour is reddish brown to dark in hilly area, very dark greyish brown to dark brown & dark and yellowish brown in coastal area. Flood plain is alluvial area. Heavy texture is predominantly clay. The soli is Nitrogen – poor, Phosphorus- medium, Potash- medium and medium in N, P high –Potash.



The soil is mainly black and Yellowish in surface colour. Depth of the soil is moderate too deep about 20 to 25cm. The predominant texture of soil is loamy and clay. The soil fertility is very poor with low nitrogen and phosphorus.

4.7 CLIMATE& METEOROLOGY

The year can be divided into four seasons. Climate is warm and dry from mid-march to June, during season of summer, climate remains warm and dry, while during rainy season, from mid-June to end of September climate is humid and pleasant. From October to November mild warm climate prevails, and from December to February climate is cold.

The Table 4.2 indicates the summary of meteorological pattern at the nearest observatory of IMD, Bharuch published by IMD.

Table 4.2: Summary Meteorological Data at nearest IMD Station –Bharuch

Location: Bharuch Gujarat ( Lat: N 21o42’, Long: E 73o 00’) Aerial Dist from Project Site: Approx. 10 km (NNW) Height of installation: 17 m above MSL. Month Temperature

(oC) Relative

Humidity (%)

Cloud Cover (Oktas)

Mean Wind

Speed(km/h)

Pre-dominant

Wind Direction

Rainfall (mm)

Max. Min. Mor. Eve. Mor. Eve. January 34.5 7.5 71 38 0.8 0.8 6.0 NE 1.2February 37.8 9.7 64 34 0.8 0.5 6.5 NE 1.4March 41.5 13.6 65 29 1.1 0.8 7.3 SW 0.2April 43.3 19.7 66 31 1.4 1.1 9.3 SW 0.5May 43.8 23.0 74 39 1.7 0.6 13.3 SW 9.2June 39.5 23.1 81 58 4.3 3.1 16.3 SW 108.5July 36.1 23.4 89 74 6.6 5.9 14.5 SW 290.4August 34.9 23.2 90 79 6.7 6.1 12.4 SW 279.1September 36.1 22.6 87 68 4.8 4.7 9.4 SW 182.7October 38.2 17.2 76 46 1.5 1.9 6.1 SW 16.8November 37.4 13.1 73 42 1.0 1.0 4.8 NE 21.9December 34.3 9.3 74 44 1.1 1.0 5.4 NE 0.2Seasonal Average Values Period Temperature

(oC) Relative

Humidity (%)Cloud Cover

(Oktas)Mean Wind

Speed(km/h)

Avg. PDW

Direction

Total Rainfall

(mm)Avg. Max.

Avg. Min.

Avg. Mor.

Avg. Eve.

Avg. Mor.

Avg. Eve.

Summer 39.0 22.5 68.3 33.0 1.4 0.8 9.9 SW 9.9Winter 32.1 12.6 69.6 38.6 0.9 0.5 5.9 NE 2.8Monsoon 32.9 25.2 86.7 69.7 5.6 4.9 13.1 SW 860.7Post monsoon 39.0 22.5 68.3 33.0 1.4 0.8 9.9

SW 9.9

Note: Winter: December, January & February, Summer: March, April & May, Monsoon: June, July, August & September, Post monsoon: October & November

(Source: Book “Climatological tables of Observatories in India (1961 - 1990)” published by IMD)

4.7.1 TEMPERATURE

The climate of Bharuch is warm and dry during the summer months but humid and pleasant during the monsoon months. The south-west monsoon from June to September brings copious rain to the territory. The winter months are generally pleasant. May is generally the hottest month with the mean daily maximum temperature recorded at 43.8 oC and mean daily minimum temperature recorded at 23 oC. January is the coldest month with the mean daily maximum temperature as 34.5 oC and mean daily minimum temperature observed as 7.5 oC.



4.7.2 HUMIDITY

Humidity is usually high during the monsoon months, generally exceeding 86.7%. Humidity decreases during the summer months. For rest of the year i.e. the period of October to February, the relative humidity ranges around 34-76%.

4.7.3 RAINFALL

About 95% of the annual rainfall is received during the southwest monsoon season i.e. from June to September, July being the month with highest rainfall. The average annual rainfall observed from the data is 912.1 mm.

4.7.4 CLOUD COVER

During the South-west monsoon months, the skies are usually heavily clouded or overcast. Cloud cover decreases during the post monsoon months. In the rest of the year the skies are mostly clear.

4.7.5 WIND PATTERN

The annual predominant wind direction comes to South West, followed by North. Winds blows mostly from the South West during summers and Monsoons. The post-monsoon & winter seasons experience a change in the wind blowing from North-east. The wind speed is high during summer and monsoon seasons, slightly moderate during winter and moderate during post-monsoon phase.

4.8 SOCIAL INFRASTRUCTURE

The infrastructure available in the study area denotes the economic well-being of the Ankleshwar Taluka. There are about 56 villages and 10 Towns in the Ankleshwar Taluka.

4.9 EDUCATIONAL FACILITIES

As per 2011 Census of India, 70 Primary schools, 6 Secondary Schools. There were no Middle School, senior secondary schools & Training institute found in 56 villages. The female literacy rate is 43%.

4.10 MEDICAL FACILITIES

Out of the 56 villages, Primary health centers in 5 villages and Primary health sub center in 21 villages. There was no Dispensary & hospitals found in 56 villages.



CHAPTER – 5

PLANNING BRIEF 5.1 PLANNING CONCEPT

The proposed project is located at Plot No. C-1/ 7131 – 7133 & C-1/7102 GIDC Estate Ankleshwar, Dist.: Bharuch, Gujarat – 393 002. The nearest city is Bharuch which is a big hub for chemical & Pharmaceutical Products and also Ankleshwar itself is a big industrial center. The region is well planned with all the basic infrastructural facilities like internal roads, water supply, arrangements for power, streetlights, solid waste disposal sites etc.

5.2 POPULATION PROJECTION

As per census 2011, the average household size is around 4 to 5. The demographic profile is presented below.

Table 5.1: Distribution of population

Sr. No. Particulars Observed values in Ankleshwar taluka 1 Total Population 4320862 No. of Households 959883 Avg. household size (person) 4-54 Male population 2307325 Male population (in %) 53.4%6 Female population 2013547 Female population (in %) 46.6%8 Sex ratio 873

(Source: Primary Census Abstract – Census of India, 2001)

5.3 AREA STATEMENT

The total area of the plot is 2915.80 m2 out of which greenbelt area of the plant is.998.83 m2 which is approx. 34.25 %. The bifurcation of the same is given in chapter-3 table 3.1.

5.4 ASSESMENT OF INFRASTRUCTURE DEMAND (PHYSICAL & SOCIAL)

In this proposed project the company will acquire plant and machinery so there will be some demand of change in physical infrastructure and social infrastructure. As manpower requirement for the proposed project shall be locally fulfilled, employment generation will lead to additional benefits to social infrastructure.

5.5 AMENITIES/FACILITIES 5.5.1 DRINKING WATER FACILITIES

There were no tap water available in 56 villages as per the Census 2011. 24 villages had wells, 21 villages had tanks/pond/lake and 34 had hand pumps. 24 villages had River/Canal passing. Power supply was also available in all the villages.

5.5.2 POWER SUPPLY FACILITIES

As per census 2011, all the villages have power supply facilities in the Ankleshwar Taluka.

5.5.3 COMMUNICATION & BANKING FACILITIES

Out of the 56 villages, Post Office is available in 2 villages, telephone facility exist in all the villages as per the 2011 census.



5.5.4 TRANSPORT FACILITIES

Bus service is available in the Ankleshwar Taluka and is the most preferable mode of transport in the Ankleshwar Taluka. The villages are well connected with the State Highways. National Highway-8 also passes from Ankleshwar. The Western railway line between Bombay to Ahmedabad passes from the Ankleshwar Taluka and Ankleshwar Town has a railway station on the same.



CHAPTER – 6

PROPOSED INFRASTRUCTURE 6.1 INDUSTRIAL AREA

The total area of the plot is 2915.80 m2. The existing built-up area is 997.41 m2 (34.20%) and open area is 589.01 m2 (20.20%).

6.2 RESIDENTIAL AREA

In the said proposal no residential area has been proposed for workers and/or for staff.

6.3 GREENBELT

Maximum open land is/will be allotted for green belt development. Greenbelt area is approximately 34.25% of total plot area.

6.4 SOCIAL INFRASTUCURE

Existing infrastructure will be sufficient to accommodate the existing load from the proposed project which is very low.

6.5 CONNECTIVITY

This proposed project is located at Plot No. C-1/ 7131 – 7133 & C-1/7102 GIDC Estate Ankleshwar, Dist.: Bharuch, Gujarat – 393 002. The site is within the GIDC Ankleshwar. The site is 3.20 km from National highway. The land and infrastructure is already available. And the raw material is easily available through the easy transport via road connectivity. The nearest railway station is Ankleshwar railway station which is 4.31 km and Surat Airport is 61.59 km from the project site.

6.6 DRINKING WATER MANAGEMENT

Drinking water will be sourced from GIDC water supply for the proposed project.

6.7 SEWERAGE SYSTEM

Domestic waste water generated from the proposed expansion project will be disposed off through soak pit / septic tank which will be @ 3.50 kl/day.

6.8 INDUSTRIAL WASTE MANAGEMENT

Industrial Effluent will be treated in the Effluent Treatment Plant at the site. Details are explained in Chapter 03, Section 3.7.3

6.9 SOLID WASTE MANAGEMENT

Hazardous wastes generated will be in the form of ETP waste from Effluent Treatment Plant, Used oil from gear boxes of the machineries & D.G. Set, Process residue from manufacturing process, discarded drums & bags from storage of raw materials. Company will provide adequate storage area for proper storage of wastes. Details of solid waste generation are given in table 3.9.

6.10 POWER REQUIREMENT & SOURCE OF SUPPLY

The power requirement will be increase to 700 kVA which will be sourced from Dakshin Gujarat Vij Company Limited.



CHAPTER – 7

REHABILITATION &RESETTLEMENT (R &R) PLAN

7.1 POLICY TO BE ADOPTED

The existing land is located in the notified industrial estate of GIDC, Ankleshwar designated for industrial use. The proposed expansion will be done on the existing land. Hence, no displacement of any population is proposed for the project. Therefore, detailed Social Impact Assessment studies or R&R action study has not been proposed.



CHAPTER – 8

PROJECT SCHEDULE & COST ESTIMATES

8.1 TIME SCHEDULE OF THE PROJECT

M/s. Danopharm Chemicals Pvt. Ltd. has obtained Consent to Operate (CC&A) for the existing products as tabulated in Table 2.1, (Copies of the same is attached as Annexure 1, for ready reference)

8.2 ESTIMATED PROJECT COST

Environment Protection has also been considered in planning the cost projection. Green belt development is also considered. The estimated project cost will be approximately 6.55 Crores.

Table 8.1: Total Capital Cost Projection

Sr. No. Purpose Total cost (Rs. In Crores)1. Plot 1.22. Building/Electrification 2.03. AHU 1.24. Equipments 0.85. Microbiology Lab 0.86. Effluent treatment plant 0.57. Greenbelt development 0.05

TOTAL 6.55CSR activities 2.5% of the capital cost




CHAPTER – 9

ANALYSIS OF PROPOSAL

9.1 FINANCIAL & SOCIAL BENEFITS

M/s. Danopharm Chemicals Pvt. Ltd. is located at Plot No. C-1/ 7131, 7132, 7133 & C-1/7102 GIDC Estate Ankleshwar, Dist.: Bharuch, Gujarat – 393 002.

The project will provide employment opportunity to 85 persons. The man-power required for the project will be employed locally from the nearby areas.

Annexure

Annexure-1 Existing CC&A

(1) 2 AMINO 5 NITRO BENZOPHENONE

Mfg. process for 2 Amino 5 Nitro Benzophenone

Charge 2-Chloro, 5-Nitro Benzophenone and Ammonia in a reactor and reflux

for 5 hrs and then heat it with Ethyl Acetate to form 2-Amino 5-Nitro

Benzophenone.

Chemical Reaction for 2 Amino 5 Nitro Benzophenone

C

O

Cl

NO2

NH3

- HClC

O

NH2

NO2

2 Chloro 5 Nitro Benzophenone

M.W.: 261.66

2 Amino 5 Nitro Benzophenone

M.W.: 241.23

Annexure-2 Process TechnologyExisting Products

Material Balance All values in kg

2-Chloro-5-nitro benzophenone 160

Liq Ammonia 270

Water wash 600 860 To ETP

10 Drying loss

Crude 160

Acetic Acid (Fresh) 15

Acetic Acid (Recycled) 305


315 Distillation Acetic acid (Recycled)

305

Residue

10

15 Drying loss

160

Drying

1) 2 Amino 5 Nitro Benzophenone

ANBP (Crude)

430

Reaction

170

Centrifuge

170

Crude ANBP

150

160

ANBP (Crude)

Reaction

Purification

480

165

165

Wet pure

Centrifuge

ANBP (Pure)

Acetic acid ML for

distillation

150

Drying

ANBP (Pure)

2. OFLOXACIN

Mfg. process for Ofloxacin

Stage-I

Charge Methanol in the reactor. To this charge O.Q-Acid and N- Methyl

Piperazine. Maintain the reaction for 10 hours. Check and transfer the reaction

mass to the crystallizer. Add Methanol and chill the reaction to ppt the

product. Centrifuge the material and wash with Methanol. The material is

unloaded and dried.

Recovery of N-Methyl Piperazine

The mother liquor is collected and distilled for the recovery of methanol. The

recovered methanol is used in the subsequent batches. The liquid mass is

made alkaline to 11 pH. Add 1800 Lts. Water. Recover N-Methyl Piperazine,

after recovery, add 4328 Lts. Water to the molten mass. Bring the pH to neutral

to precipitate the II crop material which is then centrifuged. The mother liquor

is sent to the ETP after collection of second crop. Output of final product of

700Kgs. Effluent goes to ETP of 6321 Lts. There is no gaseous emission during

process.

Chemical Reaction for Ofloxacin

+

N-Methyl PiperazineO.Q.ACID

Methanol

Ofloxacin

N

OCH3

F

F

O

O

OH

N

O

F

O

N

NCH3

CH3

CH3

NNH CH3- HF

MW: 281.21 MW: 100.16 MW: 331.38

Material balance for Ofloxacin

3. LEVOFLOXACIN

Mfg process for Levofloxacin

Stage I Charge Methanol in the reactor. To this charge L.Q-Acid and N-Methyl

Piperazine. Maintain the reaction for 10 hrs. Check TLC and transfer the

reaction mass to the crystallizer. Add methanol and chill the reaction to ppt.

the product. Centrifuge the material and wash with methanol. The material is

unloaded and dried.

Recovery of N-Methyl Piperazine The mother liquor is collected and distilled for the recovery of methanol. The


made alkaline to 11 pH. Add 1800 Lts. Water. Recover N-Methyl Piperazine,

after recovery, add 4328 Lts. Water to the molten mass. Bring the pH to neutral

to precipitate the II crop material which is then centrifuged. The ML is sent to

the ETP after collection of second crop.

Output of final product of 700Kgs. Effluent goes to ETP of 6321 Lts. There is no

gaseous emission during process

Chemical Reaction for Levofloxacin

+

Levo Q . Acid N-M ethyl P iperazine

Methanol

Levofloxacin

- HF

N

F

F

OCH 3

O

O HO

N

F

OCH 3

O

O HO

N

N

CH 3

NNH CH3

MW: 281.21 MW: 100.16 MW: 361.37

Chemical Reaction for Levofloxacin

4. CIPROFLOXACIN

Mfg. process for Ciprofloxacin

Stage I Charge Methanol in the reactor. To this charge C.Q-Acid and Anhydrous Piperazine. Maintain the reaction for 10 hrs. Check TLC and transfer the reaction mass to the crystallizer. Add methanol and chill the reaction to ppt the product. Centrifuge the material and wash with methanol. The material is unloaded and dried. Recovery of Anhydrous Piperazine The mother liquor is collected and distilled for the recovery of methanol. The recovered methanol is used in the subsequent batches. The liquid mass is made alkaline to 11 pH. Add 1800 Lts. Water. Recover Piperazine, after recovery, add 4328 Lts. Water to the molten mass. Bring the pH to neutral to precipitate the II crop material which is then centrifuged. The ML is sent to the ETP after collection of second crop. Output of final product of 700Kgs. Effluent goes to ETP of 6321 Lts. There is no gaseous emission during process. Chemical Reaction for Ciprofloxacin

+ NHNHMethanol

C.Q.Acid Anhydrous Piperazine Ciprofloxacin

NCl

F O

OHO

N

F O

OHO

N

NH

MW: 281.67 MW: 331.34MW: 86.14

- HCl

Material balance for Ciprofloxacin

5. NORFLOXACIN

Mfg. process for Norfloxacin

Stage I Charge Methanol in the reactor. To this charge NOR-Acid and Anhydrous

Piperzine. Maintain the reaction for 10 hrs. Check TLC and transfer the

reaction mass to the crystallizer. Add methanol and chill the reaction to ppt the

product. Centrifuge the material and wash with methanol. The material is

unloaded and dried.

Recovery of Anhydrous Piperazine The mother liquor is collected and distilled for the recovery of methanol. The


made alkaline to 11 pH. Add 1800 Lts. Water. Recover Piperazine, after

recovery, add 4328 Lts. Water to the molten mass. Bring the pH to neutral to

precipitate the II crop material which is then centrifuged. The ML is sent to the

ETP after collection of second crop.


gaseous emission during process.

Chemical Reaction for Norfloxacin

+

Anhydrous Piperazine

Methanol

NOR ACID

NHNHN

F

Cl

O

O

OH

CH3N

F

O

O

OH

H2CCH3

N

NH

MW: 269.66 MW: 86.14 MW: 319.33

- HCl

Norfloxacin

Material balance for Norfloxacin

6. ENROFLOXACIN

Mfg. process for Enrofloxacin

Stage- I Charge Methanol in the reactor. To this charge Enro.Q-Acid and N-Ethyl

Piperazine. Maintain the reaction for 10 hours. Check TLC and transfer the

reactions mass to the crystallizer. Add methanol and chill the reaction to

precipitate the product. Centrifuge the material and wash with methanol. The

material is unloaded and dried.

Recovery of N-Ethyl Piperazine The mother liquor is collected and distilled for the recovery of methanol. The


made alkaline to 11 pH. Add 1800 Lts. Water. Recover N-Ethyl Piperazine, after

recovery, add 4328 Lts. Water to the molten mass. Bring the pH to neutral to

precipitate the II crop material which is then centrifuged. The ML is sent to the

ETP after collection of second crop.


gaseous emission during process

Chemical Reaction for Enrofloxacin

+Methanol

N -Ethyl P iperazine EnrofloxacinC .Q .AC ID

- HClNNH CH 2CH 3

N

O

Cl

FO

O H

N

OF

O

O H

N

N

H 2C

CH 3

MW: 281.67 MW: 359.39MW: 114.19

Material balance for Enrofloxacin

1) 2-Am ino-5-Nitro Benzophenone

Chemical Reaction

+ NH3 H20 Pressure + HCl + H2O

2-Chloro-5-Nitro Benzophenone Liq Ammonia 2-Amino-5-Nitro Benzophenone

M W. 261 M W. 17 M W. 242 36

Proposed Products


2‐Chloro‐5‐nitro benzophenone 160

Liq Ammonia 270


10 Drying loss

Crude 160

Acetic Acid (Fresh) 15

Acetic Acid (Recycled) 305


315 Distillation Acetic acid (Recycled)

305

Residue

10

15 Drying loss

160

Drying

1) 2 Amino 5 Nitro Benzophenone

ANBP (Crude)

430

Reaction

170

Centrifuge

170

Crude ANBP

150

160

ANBP (Crude)

Reaction

Purification

480

165

165

Wet pure

Centrifuge

ANBP (Pure)

Acetic acid ML for

distillation

150

Drying

ANBP (Pure)

CELECOXIB

ROUTE OF SYNTHESIS

so2NH2

IoI

+

l-(4-Methylphenyll -4,4,4-trif luorobuta ne-1,3-dione

Molecular Weight : 230

Molecular Formula CrrHqFsO2

oHzN-!]-0--n

NHNH2. HCL

4-Sulphonamido PhenylHydrazine -HCL

Molecular Weight: 223Molecular Formula CeHrrNsSOzCI

HCL + 2H2O

+36+36

Il- Vcr,):/pCelecoxib

Molecular Weight : 381

Molecular Formula CrzHuFrNrOzS

2)

SPHHCL 100

Dione 104

Water 1400

Washing 200 1624 ML to ETP

Crude 180

Toluene 2871

Carbon 8

10 Carbon

Water wash 100 2989 ML for toluene recovery

15 Drying loss

2989 2825 Recovered toluene

164 Residue

Sparkler Filter


1604

Reaction

180

Centrifuge

180

Celecoxib (Crude)

2) Celecoxib

Celecoxib (Crude)

Celecoxib (Pure)

3059

Reaction Purification

ML for toluene recovery

ML for

toluene

recovery

Distillation

3049

3049

Crystallization

160

Centrifuge

145

Drying

Route of Synthesis Cis Tosylate

STAGE I

+ + 2 NaOH

Cis Bromo Benzoate Imidazole Caustic Soda MW 446 MW 68 80 C18H15BrCl2O4 C3H4N2

Toluene Caustic soda flakes + water

+ NaBr + C7H5O2Na + H2O

CIA Sodium Bromide Sodium Benzoate Water MW 329 103 144 18

C14H14Cl2N2O3

____________________________ (Signed)

Date :23.02.2015

Name: C. M. Deshmukh

Designation & Department: Manager (QC/QA)

O

O

NN

Cl

Cl

O

3)

Route of Synthesis Cis Tosylate STAGE II

+ + Triethyl amine

CIA Para Toluene Sulphonyl chloride C14H14Cl2N2O3 C7H7ClO2S

329 MW 190 101

MDC , Ethyl Acetate Triethyl amine, Liq Ammonia , water

+ Triethylamine Hydrochloride

Cis Tosylate MW 483 137

C21H19N2O5Cl2S

____________________________ (Signed)

O

O

NN

Cl

Cl

O

(STAGE I)

CBB 555

Imidazole 509

DMF 31

Toluene 2183

Water 1782

Caustic 41 416 Imidazole Recovered

Water 1759 2043 To ETP

1884 To ETP

1937 Toluene (Distilled

220 ML for recovery

35 Losses

220 199 Recovered Toluene

2 Losses

19 Residue

STAGE‐2

MDC 1316.25

PTSC 228

Stage I 325

TEA 106

Water 650

27

Water 600

65.25 MDC Loss NaOH Soln. 50 1230 To ETP

1251 MDC (Distilled)

425

25 Ethyl acetate (Distilled)

566 379 Recovered Ethyl acetate

187 Residue

13 Losses

4401

Organic Layer

2459

Aqueous Layer

3) CIS TOSYLATE

1095

Reaction

5060

Separation &

Extraction

4401

Separation &

Extraction

Organic Layer Aqueous Layer

2517 1884

1869.25

Reaction

580

Distillation

580

Crystallization

360

Centrifuge

490

Centrifuge

477

Drying

TEA Recovery & Layer

Separation

100

566

1081

Residue

1056

Distillation

1056

Crystallization

656

Distillation

ML for distillation

Aqueous Layer

1280

100

TEA Recovery

100

TEA Layer

Ethyl

Acetate

Liquid

Ammonia


Distillation

Organic Layer

1972.25

1975.25

Reaction

2652.25

3252.25

Separation &

Extraction

Reaction PH

Adjustment

325

Drying

ML for

recovery

2-Chloro Phenyl Hydrazine Hydrochl

ori

de

+ NaNO2 + 2HCl

p-Chloro Aniline Sodium Nitrite Hydrochloric Acid 4-Chloro Phenyl Hydrazine Hydrochloride

M W. 127.5 M W. 68.99 M W. 73 M W. 179

+ NaCl + O2

Sodium Sulphate Oxygen M W. 58.5 M W. 32

4)

All values in kg

HCL 224

PCA 125

Water 125

Sodium Nitrite 76.5

Water 95

ICE Water 700

Sod. Bisulphite 5

Soda Ash 94

water 523

HCl 360

Caustic 200

Water 450

2847.5 To ETP

Base 130

Water 600

HCL 80

NaCl 20

Washing 440 1080 To ETP

30 Evaporation loss

Base Formation

130

Centrifuge

Material Balance

474

Reaction Activation

1345.5

Reaction

Diazotization

160

Drying

4) 4-Chloro Phenyl Hydrazine Hydrochloride

830

190

1967.5

Reaction Coupling

Centrifuge

130

Base Formation

4-Chloro Phenyl Hydrazine Hydrochloride (Base Formation)

4-Chloro Phenyl Hydrazine Hydrochloride

Reaction

Hydrochloride

formation

2327.5

Reaction Hydrolysis

2977.5

4-Sulphanamido Phenyl Hydrazine Hydrochloride

+ NaNO2 + 2HCl Methanol

Sulphanilamide Sodium Nitrite Hydrochloric Acid 4-Sulphonamido Phenyl Hydrazine Hydrochloride

M W. 127.5 M W. 68.99 M W. 73 M W. 223.5

+ NaCl + O2

Sodium Sulphate Oxygen M W. 58.5 M W. 32


HCl 277

Sulphanilamide 160

Water 160

Sodium Nitrite 64.8

Water 70

Sod. Bisulphite 4

Soda Ash 88

Water 620

Carbon 3

Hyflow 1

6 Carbon & Hyflow

HCl 529

Water wash 100 1850.8 To ETP

Water 110

Crude 220

Methanol Wash 40 110 To ETP

40 For Methanol recovery

30 Drying loss

40 37 Recovered Methanol

0.5 Losses

2.5 Residue

1970.8

Reaction Hydrolysis

220

Centrifuge

4-Sulphonamido Phenyl Hydrazine Hydrochloride (Crude)

597

Reaction Activation

731.8

Reaction

Diazotization

1447.8

Reaction Coupling

5) 4‐Sulphonamido Phenyl Hydrazine Hydrochloride

ML for recovery

190

Drying

Methanol

RecoveryML for Methanol

recovery

220

Wet Cake Crude

4-Sulphonamido Phenyl Hydrazine Hydrochloride (Pure)

330


220

Centrifuge

1441.8

Sparkler Filter

ROUTE OF SYNTHESIS ALONG WITH THE NAME OF REAGENTS & SOLVENTS

4,4,4 – Trifluro-1-(4-methylphenyl)-Butane-1-3-Dione

-

CF3COO(CH3)2CH + Isopropyl Ester 4-Methyl Acetophenone

Mol Wt – 156 Mol. Wt. 134

Toluene,IPA SMO,HCL

+ (CH3)2CHOH 4,4,4 – Trifluro-1-(4-methylphenyl)-Butane-1-3-Dione IPA Mol. Wt. 230 + Mol wt 60

Material Balance

Trifluroacetic acid 146

Sulphuric Acid 11

Isopropyl Alcohol 114

102 Kg Recovered IPA

9 Kg Residue

Toluene 1050

SMO 70

MAP 139

Stage I 160

HCL 276

Water 700

1046 To ETP

1010 Toluene for Reuse

58 IPA for Reuse

23 Atmospheric Loss

8 Distillation Residue

20 Drying Loss

230

Drying

1349

Organic Layer

250

Distillation

250

Centrifuge

1419

Reaction

2395

Reaction

1349

Separation & Extraction

4,4,4 –Trifluro-1-(4-methylphenyl)-Butane-1.3-Dione (Stage-2)

6). 4,4,4 –Trifluro-1-(4-methylphenyl)-Butane-1.3-Dione

All values in kg

Reaction Esterification

271

Distillation

160

Product Stage I

ROUTE OF SYNTHESIS ALONG WITH THE NAME OF REAGENTS & SOLVENTS

METRONIDAZOLE BENZOATE

+

Metronidazole Benzoyl Chloride

171 140

+ HCL

Metronidazole Benzoate Hydrochloric Acid

275 36

Material Balance

Metronidazole 825 76 HCl Gas

Beta Picoline 515 4.5 CO2 gas

Soda Ash 11

Benzoyl Chloride 680

Water 1450

Sod. Bicarbonate 11 3422.5 ML for Beta Picoline recovery

Water 1461

ML for Beta Picoline recovery 3422.5 474.5 Recovered Beta Picoline

caustic flakes 25 3048 Water to ETP

Water 75

Methanol (Fresh) 1440

Methanol (Recovered) 0

Water 360

Crude 1450

Carbon 4

Hyflow 2

10 Carbon + Hyflow

1946 ML for Methanol recovery

100 Loss

ML for Methanol recovery 1946 50 Loss

1850 MeOH (Distilled)

1950.5

Reaction

Benzoylation

Metronidazole Benzoate (Crude)

7) Metronidazole Benzoate

All values in kg

Metronidazole Benzoate (Pure)

Distillation

3400.5

Reaction Quenching

1450

Centrifuge & washing

1450

Wet Cake Crude

3256


3246

Sparkler filter

1300

Centrifuge & washing

46

Residue

1200

Drying

46

Distillation

'-ry

Route of SYnthesis

Ketoconazole

nrONN{\*J bH* +

\#\,*{-o* ilprr Lo"JLo,^Jd\

clr'\r^clCis TosYlate

L-4cetyl-4-(4-hYd roxYPhe nYl )

Piperazine (AHPP)220

DN{SOI\4ethano1Ettryl acetate

*$ -.r-""ru. -*

l-"0\ ['*Efr, r. \. rt if .,---d':F*nu, ,H*{. }*fl $ ,so

$r# '*r ''*i t #' !:':s

an* man;ionwr L -# + Para Toluene sulphonic Acid

Ketoconazole

531 172

DMSO 200

AHPP 90

SMO 24

CTS 200

Acetone 200

Water 400 800 To ETP

Alkali Wash 408 470 ML for Recovery

32 Evaporation loss

175.50 Recovered DMSO

175.50 Recovered Acetone

10 Losses

109 Residue

Ketoconazole Crude 220

Ethyl Acetate 1092

Methanol 312

Carbon 12

Hyflow 2

15 Carbon

1053 ML of Ethyl acetate & Methanol for Recovery

50 400 ML for recovery

20 Loss

1163 Recovered EA

254 Recovered Methanol

10 Losses

26 residue

Distillation &

Crystallization

220

Drying

8) KETOCONAZOLE

514

Reaction

714

Reaction

252

Centrifuge

KETOCONAZOLE Crude

KETOCONAZOLE Pure

ML for recoveryDistillation

ML for RecoveryDistillation

1453

470

Centrifuge

220

200

Drying

1638

Reaction Dissolution

& Filtration

1623

Filter

570

Wash with Ethyl

Acetate + MeOH

Reaction Scheme

Ethyl Potassium Malonate

+ KOH + C2H5OH Diethyl Malonate Potassium Hydroxide Ethyl Potassium Malonate Ethyl Alcohol 160 56 170 46

Reaction Scheme

CARBO ETHOXY DI PHENYL AMINE

+ + PCL5 M WT 248.66 M WT 170.20 M WT 208.24

+ 2HCL + KCL + H3PO4

73 74.55 98

Material Balance

Stage‐1

Ethanol Denatured Toluene 1190

Diethyl Malonate 189

KOH 72

1001 Ethanol Denatured Toluene

Washing ethanol denature toluene 132 402 ML for distillation

10 Loss

ML for distillation 402 284 Distilled

73 loss

45 Residue

Stage‐2

Chloro nitro diphenyl amine 248

Stage‐1 170

1‐Chloro butane 1200

PCl 5 98

Water 450

563 Aq layer to etp

Sodium Bicarbnate solution 105

105 Aq layer to etp

Carbon 5

8 Carbon

1140 Distilled out chloro butane

Mix Xylene 65

N‐Hexane 50

Washing Xylene + n‐Hexane 40 115 Residue

145 Distilled quantity

9) Carboxy Diphenyl Amine

All values in kg

355

Centrifuge

355

Drying

260

Distillation

1600

Filter

460

Distillation

575

Residue

1708

Org Layer

1603

Separation

1608

Org Layer

1716

Reaction

2166

Quenching

1603

Separation

450

Distillation

1451

Reaction

Distillation

170

Drying

180

Wet cake

180

Centrifuge

NORFLOXACIN

+

Anhydrous Piperazine

Methanol

NOR ACID

NHNHN

F

Cl

O

O

OH

CH3N

F

O

O

OH

H2CCH3

N

NH

MW: 269.66 MW: 86.14 MW: 319.33

- HCl

Norfloxacin


Methanol 175 kg.

Nor Acid 625 kg. HCl ‐ 40 kg.

Piperazine(Fresh) 225 kg.

Piperazine(Recovered) 475 kg.

Mass - 1460 kg.

Methanol - 1400 kg.

Mass - 2860 kg.

Methanol Wash - 50 kg. ML for Piperazine recovery - 2170 kg.

Wet Cake - 740 kg.

Ev.Loss - 40 kg.

Norfloxacin (Dry) ‐ 700 kg.

10) Norfloxacin

Reaction

Crystallization

Centrifuge

Drying

Methanol Distilled ‐ 1550 kg.

ML ‐ 2170 kg. Loss - 15 kg.

Org.Layer - 605 kg.

Water - 1825 kg.

Caustic Flakes ‐ 50 kg. Piperazine recovered ‐ 475 kg.

Aqueous Layer - 2005 kg.

Water - 2000 kg.

HCl ‐ 50 kg.

Mass - 4055 kg.

Effluent to ETP - 3943 kg.

Wet Cake ‐ 112 kg.

Ev.Loss - 32 kg.

2nd Crop ‐ 80 kg.

(Recycle for next batch)

Recovery of Piperazine

Distillation

Reaction&

Layer Separation

Reaction

Centrifuge

Drying

Annexure – 3 Plot Allotment Letter

Annexure – 4 Membership Certificate of Eco-Aqua

Annexure – 5 Membership of BEIL