EQMS India Pvt. Ltd.environmentclearance.nic.in/writereaddata/EIA/... · 304-305, Rishabh Corporate Tower, Plot No. 16, Community Center, Karkardooma, Delhi – 110092, Phone: 011-30003200;

EIA/EMP Report for Expansion of Chemicals and APIs production unit by IOLCP

EQMS India Pvt. Ltd. 1

December, 2018

EQMS India Pvt. Ltd.

304-305, Rishabh Corporate Tower, Plot No. 16,

Community Center, Karkardooma, Delhi – 110092,

Phone: 011-30003200; E-mail : [email protected];

Website : www.eqmsindia.com

Environmental Impact Assessment Report for

Expansion of Chemicals and APIs production

Unit.

By

M/s IOL CHEMICALS AND PHARMACEUTICALS

LIMITED

Village Fatehgarh Channa on Mansa Road Tehsil and

District Barnala, Punjab-148101

mailto:[email protected]

http://www.eqmsindia.com/



Table of Contents

Chapter 1. INTRODUCTION ...................................................................................... 12

1.1. IMPORTANCE AND NEED OF AN EIA ................................................................... 12

1.2. PROJECT & PROJECT PROPONENT ................................................................... 12

1.3. IMPORTANCE AND BENEFIT OF THE PROJECT ................................................. 13

1.4. PURPOSE OF THE EIA STUDY ............................................................................. 14

1.5. PROJECT LOCATION ............................................................................................ 14

1.6. REGULATORY FRAMEWORK ............................................................................... 17

1.7. PUBLIC HEARING .................................................................................................. 17

1.8. SCOPE & METHODOLOGY OF THE STUDY ......................................................... 22

1.9. APPROVED TERMS OF REFERENCE FOR EIA STUDY BY EAC ........................ 23

1.8.1 TOR Compliance Status ........................................................................... 23

1.10. STRUCTURE OF THE REPORT ............................................................................. 31

Chapter 2. Project Description .................................................................................... 33

2.1. NEED AND JUSTIFICATION OF THE PROJECT ................................................... 34

2.2. SITE DETAILS AND LOCATION ............................................................................. 34

i. Site Location ............................................................................................. 34

2.3. Approach to Site ...................................................................................................... 36

2.4. LAND REQUIREMENT ........................................................................................... 36

2.5. PRODUCTS WITH CAPACITIES FOR THE PROPOSED PROJECTS ................... 38

2.6. MANUFACTURING PROCESS ............................................................................... 40

2.7. DETAILS OF RAW MATERIALS, CONSUMPTION AND SOURCE ...................... 109

2.7.2. Raw Material Storage (Liquids) ............................................................... 119

2.8. INFRASTRUCTURE & UTILITIES REQUIRED FOR THE EXPANSION PROJECT

119

2.8.1. Land ........................................................................................................ 119

2.8.2. Water ...................................................................................................... 119

2.8.3. Power ..................................................................................................... 121

2.8.4. Boiler ...................................................................................................... 121

2.8.5. Fuel ......................................................................................................... 121

2.8.6. Man Power .............................................................................................. 122

2.8.7. Facilities for worker ................................................................................. 122

2.8.8. Wastewater treatment: ............................................................................ 122



2.8.9. Multiple Effect Evaporator ....................................................................... 127

2.9. SOLVENT MANAGEMENT SYSTEM: ................................................................... 129

2.10. AIR EMISSION AND AIR POLLUTION CONTROL MEASURES ........................... 131

2.11. NOISE ................................................................................................................... 134

2.12. HAZARDOUS WASTE MANAGEMENT ................................................................ 134

2.13. AUXILIARY & GENERAL WELFARE FACILITIES................................................. 136

2.13.1. Fire and Safety System: .......................................................................... 136

2.14. OHS System.......................................................................................................... 136

2.15. PROJECT COST ESTIMATES & IMPLEMENTATION SCHEDULE ...................... 137

2.16. CSR Activities ........................................................................................................ 137

Chapter 3. Description of environment ...................................................................... 139

3.1 Background and Salient Environmental Features of the Study Area ...................... 139

3.1.1 Environmental Setting and Salient Environmental Features of the Project Area .... 139

3.1.2 Primary Data Collection: Monitoring Plan and Quality Assurance Procedures ....... 144

3.2 Physical Environment ............................................................................................ 147

3.2.1 Topography ........................................................................................................... 147

3.2.2 Drainage ................................................................................................................ 147

3.2.3 Geology & Hydrogeology ....................................................................................... 147

3.2.4 Ground water Resources ....................................................................................... 147

3.2.5 Depth to Ground Water Table ................................................................................ 147

3.2.6 Seismicity of the Study Area .................................................................................. 149

3.3 Land use ............................................................................................................... 149

3.4 Meteorology........................................................................................................... 152

3.4.1 Met Data Generated at Site ................................................................................... 153

3.5. Air Environment ..................................................................................................... 155

3.5.1. Selection of Monitoring Stations .............................................................. 155

3.5.2. Analysis of Ambient Air Quality of the Project Area ................................. 155

3.5.3. Observation on Ambient Air Quality ........................................................ 157

3.5.4. Comparison of Ambient Air Quality Data with Available Secondary Data 158

3.6. Noise Environment ................................................................................................ 158

3.4.2 Observation on Ambient Noise Quality: ................................................................. 159

3.7. Traffic Study .......................................................................................................... 160

3.8. Water Quality ......................................................................................................... 160

3.8.1. Ground Water Quality ............................................................................................ 160



3.8.2. Surface Water Quality ........................................................................................... 164

3.9. Soil Quality ............................................................................................................ 168

3.8.1. Methodology ........................................................................................... 168

3.8.2. Soil Sampling Locations .......................................................................... 169

3.8.3. Analysis of Soil Samples ......................................................................... 169

2.4 Interpretation of Analytical Results & Conclusion ............................................. 170

3.10. Ecology ................................................................................................................. 171

3.10.1. Flora of Study Area ................................................................................. 172

3.11. Socio-Economic Environment ................................................................................ 178

Chapter 4. AnticIpated environmental impacts and mitigation mearsures ................. 194

4.1. General ................................................................................................................. 194

4.2. Construction Phase ............................................................................................... 194

4.2.1. Air Environment ..................................................................................................... 194

4.2.2. Operation Phase ................................................................................................... 195

4.2.3. Model Details ......................................................................................................... 195

4.2.4. Predicted GLC due to Proposed Project ................................................................ 196

4.2.5. Meteorological Data ............................................................................................... 197

4.2.6. Receptor Locations................................................................................................ 197

4.2.7. Summary of Predicted GLC‘s ................................................................................ 197


4.3.1. Construction Phase ............................................................................................... 204

4.3.2. Operation Phase ................................................................................................... 204

4.4. Water Environment ................................................................................................ 205

4.4.1. Construction Phase ............................................................................................... 205

4.4.2. Operation Phase ................................................................................................... 205

4.5. Land Environment ................................................................................................. 205

4.6. Biological Environment .......................................................................................... 206

4.7. Socio – Economic Environment ............................................................................. 208

4.8. Infrastructure ......................................................................................................... 210

Chapter 5. Environment Management Plan .............................................................. 212

5.1. Introduction ........................................................................................................... 212

5.2. Objectives of EMP ................................................................................................. 212

5.3. Components of EMP ............................................................................................. 212

5.4. Air Environment ..................................................................................................... 212



5.4.1. Air Pollution Control Measures .............................................................................. 213

5.5. Fly ash Management ............................................................................................. 215


5.7. Water Environment ................................................................................................ 217

5.7.1. Construction Phase: ................................................................................ 217

5.7.2. Strom water management ....................................................................... 219

5.8. Biological Environment .......................................................................................... 219

5.9. Green Belt development plan ................................................................................ 219

5.10. Land Environment ................................................................................................. 221

5.11. Resource Conservation/ Waste Minimization ........................................................ 222

5.12. Facilities for Employees ......................................................................................... 224

5.13. IOLCP HSE Policy ................................................................................................. 224

5.14. Environment Management Cell ............................................................................. 225

5.14.1. Post – Operational Monitoring Program .................................................. 228

5.14.2. Budget for environmental management plan ........................................... 228

Chapter 6. Risk Assessment& DISASTER MANAGEMENT PLAN ........................... 230

6.1. Introduction ........................................................................................................... 230

6.2. Risk Assessment ................................................................................................... 230

6.3. Risk Screening Approach ...................................................................................... 233

6.4. Hazardous Materials Storage ................................................................................ 245

6.5. QRA Approach ...................................................................................................... 245

6.6. Thermal Hazards ................................................................................................... 246

6.7. Toxic Release ........................................................................................................ 248

6.8. Data Limitations ..................................................................................................... 248

6.9. Likely Failure Scenarios ........................................................................................ 248

6.10. Weather Effect ....................................................................................................... 248

6.11. Incidents Impacts .................................................................................................. 249

6.12. Consequential Impacts .......................................................................................... 255

6.13. Thermal and Explosion Hazards ............................................................................ 255

6.14. Toxic Hazards ....................................................................................................... 255

6.15. Other Hazards ....................................................................................................... 256

6.16. Other Toxic Hazards .............................................................................................. 256

6.17. General Control Measures ..................................................................................... 256



6.18. Flammable Gas Fires ............................................................................................ 256

6.19. Process Safety System to be Developed at IOLCP ............................................... 256

6.20. Safety System for Toxic Material Handling ............................................................ 257

6.21. WORKPLACE MONITORING PLAN ..................................................................... 258

6.22. Arrangement for ensuring health and safety of workers engaged in handling of toxic

materials ............................................................................................................................ 259

6.23. Safety Recommendations...................................................................................... 259

6.23.1. Commonly Recommended Control Measures ....................................................... 259

6.23.2. Occupational Health and Safety ............................................................................ 260

6.23.3. Transportation: ...................................................................................................... 261

6.24. Emergency facilities ............................................................................................... 266

Objectives ......................................................................................................................... 266

6.25. Emergency Management Plan [EMP] .................................................................... 266

6.26. Conclusion & Recommendations ........................................................................... 266

Chapter 7. SUMMARY AND CONCLUSION ............................................................. 267

Chapter 8. DISCLOSURE OF CONSULTANTS ....................................................... 272



List of Tables

Table 1.1 : Details of permits and clearance applicable ....................................................... 17

Table 1.2 : Compliance Status of Terms of Reference ........................................................ 24

Table 2.1 : Salient features ................................................................................................. 34

Table 2.2 : Land Distribution at site ..................................................................................... 36

Table 2.3 : List of Products.................................................................................................. 38

Table 2.4 : List of Raw materials, consumption and its source .......................................... 109

Table 2.5 : Area Breakup .................................................................................................. 119

Table 2.6 : Water Breakup ................................................................................................ 119

Table 2.7 Stacks in the API Plant with emission details ..................................................... 131

Table 2.8 : Hazardous waste details ................................................................................. 134

Table 3.1 : Salient Environmental Features of Proposed Site ............................................ 140

Table 3.2 : Summary of Methodology for Primary/Secondary Baseline Data Collection .... 144

Table 3.3 : Land use of the Study Area ............................................................................. 150

Table 3.4 Long Term Meteorological Data of Ludiana (30 years average) ........................ 152

Table 3.5 Site Specific Meteorological Data ...................................................................... 153

Table 3.6 : Ambient Air Quality Monitoring Locations ........................................................ 155

Table 3.7 : Ambient Air Quality Monitoring Results for PM2.5 and PM10(24-hour average) .................................................................................................................................. 156

Table 3.7 Conti... Ambient Air Quality Monitoring Results for SOx and NOx (24-hrs avg.) 156

Table 3.7 Conti... Ambient Air Quality Monitoring Results for SOx and NOx (24-hrs avg.) 156

Table 3.8 Month wise AAQ Data (Jan to May 2018) .......................................................... 158

Table 3.9 Ambient Noise Quality Monitoring Locations ..................................................... 158

Table 3.10 Ambient Noise Quality in the Study Area ......................................................... 159

Table 3.11 Ground Water Sampling Locations .................................................................. 160

Table 3.12 Ground Water Quality in the Study Area .......................................................... 161

Table 3.15 Continued..........Ground Water Quality in the Study Area ............................... 162

Observation on Water Quality ........................................................................................... 164

Ground water .................................................................................................................... 164

Table 3.13 CPCB Best Designated Use Standard (Source-CPCB) ................................... 164

Table 3.14 Sampling Location Surface Water ................................................................... 165

Table 3.15 Surface Water Quality in the Study Area ......................................................... 166

Table 3.16 : Soil Sampling Locations ................................................................................ 169

Table 3.17 Physiochemical Characteristics of Soil ............................................................ 169

Table 3.18 Type of Forest in Barnala District .................................................................... 171

Table 3.19 List of Common Plant Species Present in Study Area ..................................... 172



Table 3.20 List of Medicinal Plants and their Medicinal Value ........................................... 174

Table 3.21 : Mammalian Fauna reported in study area ..................................................... 176

*Conservation status is LC (Least Concerned species) ..................................................... 176

Table 3.22 : Reptiles and Amphibian observed in Study Area ........................................... 176

Table 3.23 : Avifauna Sighted during the primary survey .................................................. 177

Table 3.24 : Caste-wise Population Distribution of 2.0-km Radial Study Zone................... 179

Table 3.25 : Caste wise Population Distribution of 10-km Radial Study Area .................... 180

Table 3.26 : Male-female wise Literates & Illiterates ......................................................... 182

Table 3.27 Distribution of Work Participation Rate ............................................................ 184

Table 3.28 Village wise Occupational Pattern in the Study Area ....................................... 185

Table 3.29 : Composition of Non-Workers ......................................................................... 187

Table 3.30 Village wise Basic Amenities Availability ......................................................... 191

Table 4.1 : Stack emissions .............................................................................................. 197

Table 4.2 : Summary of Maximum 24-hour Incremental GLC due to the Proposed Project Stacks ........................................................................................................................ 198

Table 4.3 Ambient Air Quality Monitoring Results (24-hour average) ................................ 198

Table 4.4 Ambient Air Quality Monitoring Results (24-hour average) ................................ 198

Table 5.1 : Design Features for Minimization of Fugitive Emissions .................................. 214

Table 5.2 : Ambient air environment impact and management plan ................................... 214

Table 5.3 : Ambient noise environment impact and management plan .............................. 216

Table 5.4 : Water environment impact and management plan ........................................... 218

Table 5.5 : Impact and management plan ......................................................................... 222

Table 5.6 : Budget for environmental management plan ................................................... 229



List of Figures

Figure 1.1 : Plant coordinates ............................................................................................. 15

Figure 1.2 : Project Location (on Toposheet) ...................................................................... 16

Figure 2.1 : Project Location Map ....................................................................................... 35

Figure 2.2 : Site Layout ....................................................................................................... 37

Figure 2.3 : Process flow diagram ....................................................................................... 42

Figure 2.4 : Process flow diagram of Acetic Anhydride ........................................................ 44

Figure 2.5 : Process flow diagram ....................................................................................... 46

Figure 2.6 : Process flow diagram of Iso Butyl benzene ...................................................... 48

Figure 2.7 :Process flow diagram of Diclofenac Sodium ...................................................... 49

Figure 2.8 : Process flow diagram of Metformin Hydrochloride ............................................ 51

Figure 2.9 : Process flow diagram of Fenofibrate ................................................................ 52

Figure 2.10 : Process flow diagram of Clopidogrel Bisulphate ............................................. 55

Figure 2.11 : Process flow diagram of Amlodipine ............................................................... 59

Figure 2.12 : Process Flow diagram of Ibuprofen ................................................................ 63

Figure 2.13 : Process Flow Diagram ................................................................................... 65

Figure 2.14 : Process flow diagram ..................................................................................... 67


Figure 2.16 Process flow diagram Ursodeoxycholic acid ..................................................... 71



Figure 2.19 Process flow diagram ....................................................................................... 78


Material balance of of Pentaprozole .................................................................................... 82









Figure 2.29 : Process flow diagram ................................................................................... 100

Figure 2.30 :Process flow diagram .................................................................................... 101










Figure 2.1: Proposed Water Balance (After expansion) ..................................................... 120

Figure 2.38 Flow Diagram of MEE .................................................................................... 128

Figure 3.1 Road Connectivity Map .................................................................................... 140

Figure 3.2 Location Map of Study area ............................................................................. 142

Figure 3.3 Google Map of 10 km Study area ..................................................................... 143

Figure 3.4 Environment Sampling Location Map ............................................................... 146

Figure 3.5 Depth to water level (Pre Monsoon season) ..................................................... 148

Figure 3.6 Depth to water level (Post Monsoon Season) ................................................... 148

Figure 3.7 Seismic Zones Map .......................................................................................... 149

Figure 3.8 Area statistics for Land Use / Land Cover Categories in the Study Area .......... 150

Source: Interpretation of Satellite image............................................................................ 151

Figure 3.9 Land Use Map of the Study Area (10 km Radial Zone)..................................... 151

Figure 3.10 Wind Rose Diagram of Study Area (Pre Monsoon Season)............................ 154

Figure 3.11 Wind Class Frequency Distribution ................................................................. 154

Figure 3.12 Figure: Male-Female wise Population Distribution in the Study Area .............. 181

Figure 3.13 : Scheduled Caste Population in the Study Area ............................................ 181

Figure 3.14 : Male-Female wise Distribution of Literates & Illiterates ................................. 182

Figure 3.15 : Workers Scenario of the Study Area ............................................................ 185

Figure 3.16 : Composition of Main Workers Population .................................................... 186

Figure 3.17 : Composition of Marginal Workers................................................................. 187

Figure 3.18 : Composition of Non-Workers ....................................................................... 188

Figure 5.1 National Energy Conservation Award - 2016 .................................................... 224

Figure 5.2 : HSE Policy ..................................................................................................... 225



List of Annexure

Annexure I : Nabet Certificate

Annexure II : Copy of earlier EC

Annexure III : Copy of approval for change in product mix

Annexure IV : Copy of certified Compliance

Annexure V : Copy of consent approval

Annexure VI : Copy of TSDF membership

Annexure VII : Public Hearing Minutes of Meeting

Annexure VIII : Surface water permission and Letter for Ground water abstraction

permission

Annexure IX : Baseline Environmental Monitoring report

Annexure X : Annual Health checkup report

Annexure XI : PPCB ETP testing report

EXECUTIVE SUMMARY - EIA/EMP Report for expansion of Chemicals and APIs production unit by IOLCP


EXECUTIVE SUMMARY

Project & Project Proponent

M/s IOL Chemicals & Pharmaceuticals Limited (IOLCP) is based at Village Fatehgarh Channa on Mansa

Road, Tehsil & District Barnala Punjab. It is spread over 62 acres.

IOLCP is proposing for expansion of existing unit by addition some new products and increasing the

capacity of existing product. Hence applied in MOEF&CC and received TOR on 1th June 2018 (Letter No.

J-11011/976/2008-IA-II(I)) for proposes expansion of existing products and addition of new products from

the capacity of 543.45 TPD to 671.95 TPD at its existing location (Village Fatehgarh Channa, Mansa

Road, District Barnala – 148101, Punjab) The total investment is ~ Rs 205 crores. The capital investment

towards environment management is estimated to be Rs.690 lacs and recurring cost will be Rs. 483 lacs .

Figure: Location Map of 10 km radius

Connectivity:

The proposed site is at a distance of about 1.45 km,SE from village Fatehgarh Channa, State

Highway 13 is at a distance of 0.81 km. Nearest Railway station is Barnala railway station 8.69

km from the project site and Chandigarh airport is approx. 130 km away in NE direction from

project site (aerial distance). No National Parks, Wildlife Sanctuaries, Tiger/ Elephant Reserves,

Wildlife Corridors etc. falls within 10 km radius from the plant site.



PUBLIC HEARING

As per Ministry of Environment and Forest, GOI, New Delhi vide its Notification No. S.O.1533

dated September 14, 2006 and subsequent amendment thereof. A draft EIA report has

submitted (Prepared as per prescribe TOR) at Punjab Pollution Control Board report. Further an

advertisement was published in three prominent newspapers, ‘The Tribune’, ‘Ajit’ and

‘Spokesman’ dated 25 Sep 2018. In the presence of ADC-Barnala, Representative of Punjab

Pollution Control Board, Patiala & Regional office PPCB, Sangrur with near by public, Public

Hearing was conducted on 26th Oct 2018 at Village Fatehgarh Channa, Mansa Road, Barnala,

Punjab for the Proposed Expansion of Chemicals and APIs production unit, from capacity of

543.45 TPD to 671.95 TPD by M/s IOL Chemicals & Pharmaceuticals Limited. which is covered

under Category-A. Most of the issue raised during public hearing were related to employment,

CSR and clarity oriented related to environmental aspects and the proceeding are addressed

Project Description:

The present EIA study covers enhancement of existing capacity and addition of new products

hence the capacity increases from 543.45 TPD to 671.95 TPD for the manufacturing of bulk

drug and API drugs production unit. IOLCP has applied for TOR in 19 April 2018 and Standard

TOR has been issued on 1st June 2018.

All the products are not manufactured at a time. The likely production capacities of the products

will depend upon market demand but limited to the sanctioned capacity as mentioned above.

Description of Environment:

Primary baseline data has been collected as per the TOR prescribed by MOEF during 15th

March 2018 to 15th June 2018 for one complete season Baseline Data was generated by

following the standard procedures of the Ministry of Environment & Forests and the Central

Pollution Control Board.

Air Environment: Ambient air quality was monitored at eight locations in the study area. The

locations were selected as per CPCB guidelines. The mean concentration of PM2.5 in all location

ranges between 42 to 48 µg/m3.. The mean concentration of PM10 in all location ranges between

85 to 93 µg/m3 This may be due to the dust generated from thrashing of Wheat crop in the

agricultural field, presence of industries in addition to plying of heavy traffic such as trucks and

other combustion engine vehicles in nearby roads. Mean value are found well within National

Ambient Air Quality standards. SO2 level in all the location ranges between 6.2-20.5 µg/m3,

NOx level in all the location ranges between 14.0-41.2 µg/m3, which was found well within

National Ambient Air Quality standards i.e. NAAQMS (80µg/m3). The NH3 level in all monitoring

locations ranges between 9 to 23 µg/m3. The NH3 level in all monitoring location is under

permissible limit i.e. NAAQMS 400 µg /m³.The 8 hrs. CO level in all monitoring locations ranges

between 0.14 to 0.81 mg/m³.



Noise Environment:The ambient noise level of all the monitoring locations were found well

within the National Ambient Noise Quality Standards prescribed for industrial (Standards - 75

dBA during day time and 70 dBA during night time) residential area (Standards - 55 dBA during

day time and 45 dBA during night time) and commercial area (Standards - 65 dBA during day

time and 55 dBA during night time)

Water Quality: Six surface water samples and eight groundwater samples were collected from

the area for chemical and biological analysis. Overall the ground water quality of the study area

is found well within the permissible limits. No metallic and bacterial contaminations were

observed in ground water samples.

Surface water quality is determined by the help of water quality criteria defined in CPCB best

designated uses criteria. Surface water monitoring is performed for nalla near project site at 100

upstream and downstream point of the project site high bacterial contamination were observed

in Nala water quality meeting the BDU criteria Class D which is fit for propagation of wildlife and

fisheries.

Canal Water quality: The canal water quality is good for Drinking water source after

conventional treatment and disinfection and meeting the class C of Best designated uses of

CPCB.

Pond Water Quality: Bacterial contaminations were observed in pond water samples. Dissolve

oxygen is found within the range while BOD was found slightly high than the Class C of Best

designated uses. Hence the pond water is fit for Propagation of Wild life and Fisheries and

meeting the criteria D of Best designated uses of CPCB.

Soil Quality: The soil quality of study area is sandy loam. The pH and conductivity of the soil is

within acceptable range. The soil analysis describes that the soil of the study area is moderately

fertile.

Sensitive Ecosystem:There are no environmentally sensitive components such as National

Park, Wildlife Sanctuary, Elephant / Tiger Reserve, migratory routes of fauna and wet land

present within 10 Km radius of plant site.

Socio economic environment: As per Census of India- 2011, Barnala district had a total

population of 5, 95,527 out of which 3, 17,522 are males and 2, 78,005 are females. Males

constitute the 53.31% and female constitutes 46.68 % of total population. Barnala has an

average literacy rate 67.8% which is 7.5% more than the 2001 Census data. The percentage of

decadal growth in population has been 13.0% during 2001-11 and sex ratio (number of females

per 1000) has been 876 in 2011 as compared to 872 in 2001 .In the district 0-6 years of

population in the district has been 10.9 which is on the decreasing trend in comparison of 2001

when it was 13.3% . As per the census records 2011, in Barnala district there are 78.5% Sikhs,

19.0% Hindus, 2.2% Muslims, 0.1% Christians, Jains and Buddhists are negligible.



Environmental Impact and Mitigation Measures

Air Quality:

The main sources of air pollution due to the operation of the plant are the Boiler, process stack /vent,

pump, DG set and other stacks. Gaseous emission from fuel burning, consist of common pollutants like

PM, SO2, NO2, and HCL would be discharged into atmosphere through Stack of suitable height as per

CPCB norms. The operation of centrifuging/ filter will be done in closed equipment to avoid any vapours

coming out in the local atmosphere. The vents of centrifuges / filters will be connected to scrubbers.

For the proposed project, computations of 24-hour average ground level concentrations were carried out

using ISCST3 model, which is a recommended model by USEPA for prediction of air quality from point

area.

Table: Summary of Maximum 24-hour Incremental GLC due to the Proposed Expansion

Project Stacks

Parameters Maximum incremental GLC

(µg/m³)

Distance

(Km) Direction

PM 0.95 1.6 SE

SO2 0.64 1.6 SE

NOx 3.1 1.6 SE

HCL 0.23 1.6 SE

The nearest settlement in downwind direction is Fatehgarh channa village (towards SE) at a distance of

1.68 km. As per baseline data of mean AAQ for PM at Fatehgarh channa village is 92 µg/m³ and with this

proposed project, 0.95 µg/m³ rise in GLCs so PM level will be 92.95 µg/m³. The Particulate Matter in the

study area is contributed mainly by commercial activities and traffic movement (vehicular emissions), re-

suspended dust from paved and unpaved roads and open uncovered areas as well as from industrial

activities.

Maximum baseline GLC for SO2 (Process and utilities) at downwind direction (SE) was as 11.8 µg/m³

observed at Fatehgarh Channa village. With this proposed expansion project SOx level may increase by

0.61 µg/m³ so post project level of SOx is 12.41µg/m³. Maximum baseline GLC for NOx was as 22.70

µg/m³ observed at Fatehgarh channa village . With this proposed project NOx concentration is 3.1 µg/m³

so rise in GLC of NOx concentration is 25.80 µg/m³. It can be concluded that with the proposed project

all the AAQ parameters will remain within the NAAQ norms.

As is evident from the table and discussion above, there will be no adverse impacts on the surrounding

area (all pollutants post project GLC will be well within NAAQ norms). Highly efficient air pollution control

systems have been adopted to mitigate particulate matter as well as gaseous emissions in the ambient

environment.



Noise Quality:

The main source of noise generation during operation stages are mainly from pumps, blowers,

compressors, DG sets, vehicle movement for transportation of raw materials, finished goods

etc. DG sets will be provided with acoustics enclosures. Mufflers, silencers, acoustics treatment

of room will be done wherever required. Equipment will be maintained so that noise level does

not increase due to improper maintenance. Material handling operations and movement of

vehicles will be properly scheduled to minimize construction noise. Workers working in noisy

areas will be given ear plugs. The noise level will be restricted within the plant boundary to meet

the standards. Existing greenbelt developed within the plant premises will also act as a barrier

to the propagation of noise from the factory premises. This shall further reduce the noise levels

appreciably. Hence, no significant impact is envisaged.

Water Quality: Total water requirement–1800 KLD (Fresh water 1456 KLD and Recycle water

344 KLD).Water requirement will be made available through ground water and surface water.

Low TDS Effluent Treated in To ETP. ETP comprises of Four Stage , Two Stage Anaerobic ,

One Stage Aerobic and One Stage Tertiary. After treatment treated effluents discharge in to

plantation area within premises. High TDS effluent Treated in to MEE. Condensate recovery will

be reused in plant. Concentrated stream will be sent to ATFD for further treatment. MEE salt will

be sold out to end users.

Solid and Hazardous Wastes Disposal:

All the solid and hazardous waste generated from the proposed unit shall be disposed as per

the norm. Minor quantities of construction waste will be generated in the form of packaging

material and construction waste. Proper care will be taken for handling and reduction of the

solid waste generated during construction phase. ETP sludge/ process residue generated

during operation phase shall be disposed as per the hazardous wastes management, handling

and Trans-boundary movement Rule 2016 and amendment thereof.

Impact on Ecology: No national park, wildlife sanctuary, biosphere reserve exists within 10 km

area of the project. No endangered or rare or threatened plant or animal species was observed

within 10 km area of the project site. The impact on the surrounding ecology during the

operation of the project will mainly occur from the deposition of air pollutants. Air pollution

affects the biotic and abiotic components of the ecosystem individually and synergistically with

other pollutants. Chronic and acute effects on plants and animals may be induced when the

concentration of air pollutants exceeds threshold limits. Particulate emission and other gaseous

emissions from the proposed plant are the major pollutant that may affect the ecology of the

area. However the AAQ modeling proves that in worst condition the concentration of the PM

and other gaseous emission will not exceeds the AAQ standards. Further the mitigation

measures have been suggested for the same. By adopting the mitigation measures suggested

the impact due to operation of the proposed expansion will be negligible.



Risk Assessment and Disaster Management Plan: The hazard potential of chemicals and

estimation of consequences in case of their accidental release during storage, transportation

and handling has been identified and risk assessment has been carried out to quantify the

extent of damage and suggest recommendations for safety improvement for the proposed

facilities. Risk mitigation measures based on MCA analysis and engineering judgments are

incorporated in order to improve overall system safety and mitigate the effects of major

accidents.

An effective Disaster Management Plan (DMP) to mitigate the risks involved has been prepared.

This plan defines the responsibilities and resources available to respond to the different types of

emergencies envisaged. Training exercises will be held to ensure that all personnel are familiar

with their responsibilities and that communication links are functioning effectively.

Environmental Management Plan (EMP): EMP for effective management of environmental

impacts and ensuring overall protection of the environment through appropriate management

procedures has been recommended in the EIA report. The capital investment towards

environment management is estimated to be Rs.690 lacs and recurring cost will be Rs. 483

lacs.This amount shall be used for procurement of air and water pollution control devices, noise

pollution control, monitoring devices, strengthening of environment Cell, occupation health and

safety department, green belt development, etc.

ENVIRONMENT MONITORING PROGRAM

Post project environmental monitoring is important in terms of evaluating the performance of

pollution control equipment’s installed in the project. The sampling and analysis of the

environmental attributes will be as per the guidelines of CPCB/SPCB. The frequency of

sampling and location of sampling will be as per the directives of Punjab Pollution Control

Board.

Green belt development: IOLCP has planted approx 26000 tree/shrubs and herbs in existing

greenbelt. The tree species like Eucalyptus, neem, Daikan, sadabahar, Ficus spp., Champa,

kadam gulmohar along with shrubs and herbs has been planted under existing greenbelt.

Further maintenance of the existing greenbelt shall be done on regular basis for which IOL

Chemical has already kept a budget for Rs. 50 lakhs as a capital cost.

CSR Plan: Unit has committed to spend about Rs. 1.53 crores (0.75% of the capital investment)

towards CER. But the Approved TOR is for 2.5 % of the project cost and IOLCP follow the OM

issued on dated 1st May 2018, hence earmarked the fund of Rs 1.53 crores. The amount will be

spending in next 3 years for infrastructure development of surrounding area.

Project Benefits

Proposed expansion project will result in considerable growth of stimulating the industrial

and commercial activities in the state. Small and medium scale industries may be further

developed as a consequence.



The project will be beneficial in govt’s target of increase the production capacity and yield in

the field of pharmaceuticals.

Increased revenue to the state by way of royalty, taxes and duties;

Overall Growth of the neighbouring area viz. Health and family welfare; Watershed

development; Sustainable livelihood and strengthening of village Self Help Groups; and

Infrastructure development.

In operation phase, the proposed plant would require significant workforce of non-technical

and technical persons.

Migration of persons with better education and professional experience will result in increase

of population and literacy in the surrounding villages.

Civic amenities will be substantial after the commencement of project activities. The basic

requirement of the community needs will be strengthened by extending healthcare,

educational facilities to the community, building/strengthening of existing roads in the area.

The local population will be given preference to employment on the basis of their eligibility

and company requirement. The employment potential will ameliorate economic conditions of

these families directly and provide employment to many other families indirectly who are

involved in business and service oriented activities. The employment of local people in

primary and secondary sectors of project shall upgrade the prosperity of the region. This in-

turn will improve the socio-economic conditions of the area.



CHAPTER 1. INTRODUCTION

1.1. IMPORTANCE AND NEED OF AN EIA

Government of India, as per its policy has given emphasis on Sustainable

Development. While it is supporting the industrial growth, the environmental protection

has been made the integrated criteria for this support. In line with this policy, Ministry

of Environment, Forest and Climate Change has defined elaborated ‗Environment

Clearance (EC)‘ framework under The Environmental (Protection) Act, 1986

(Environmental Impact Assessment Notification, 2006) for establishing/expanding an

industry/development project. The EC process takes into consideration local

conditions, public concerns, effectiveness of impact assessment and proposed

mitigation measures in sustaining environmental equilibrium. The base

documentation/study report, called Environmental Impact Assessment (EIA) detailing

baseline conditions, environmental impacts, mitigation measures and management

plan is required to be prepared for start of EC process. Prior Environmental Clearance

is required from concerned authorities for all projects and activities mentioned in

―Schedule‖ as per Environmental Impact Assessment notification dated September 14,

2006. The project comes under ―project and activity-5 (f) of schedule‖ As the site

located outside the industrial area. Considering the products portfolio, the proposed

projects falls in ―Category A‖ of Schedule of the EIA notification which requires

Environmental Clearance (EC) from MoEFCC, New Delhi. Public Hearing is applicable

for the API drugs project (if site not located in notified industrial area). EIA report is

mandatory for appraisal by expert committee prior to EC. Since EIA preparation and

compliance to EC requirement is time consuming, MoEF&CC has started accepting

one season based EIA study to reduce the overall clearance cycle time.

1.2. PROJECT & PROJECT PROPONENT

IOL Chemicals & Pharmaceuticals Limited (IOLCP) is based at Village Fatehgarh

Channa on Mansa Road, Tehsil & District Barnala Punjab. It is spread over 62 acres.

IOLCP is the leading chemical and bulk drugs manufacturer of India as well as with

global presence in chemical and pharmaceuticals market.

IOLCP has adapted "Go Green" principles, with special units for designing

environmentally-friendly production processes in place in the Ethyl Acetate, IBB and

MCA Divisions. In the energy sphere, guidelines are in place to use passive

techniques for heating, cooling and air flow, improve air conditioning and heating

systems, and use natural light and insulation. Some major achievements of IOL

Chemicals & Pharmaceuticals Limited (IOLCP) are summarized with following

accreditation and awards.

The unit is a ISO 9001:2015, ISO 14001:2015 & ISO 18001: 2007 The unit is WHO GMP, Eu, GMP and USFDA compliant.

This chapter provides background information of the project, need of the project,

need of the EIA study, scope and EIA methodology adopted and structure of the

report.



The unit is already operating with Environmental Clearance dated August 24,2009 vide letter No. J-11011/976/2008-IA-II (I) and all consents from State Pollution Control Board.

The unit is awarded with the National Energy Conservation Award Consecutively for the years 2005,2006, 2007, 2008,2009,2010,2011,2012,2013,2014,2016 by Ministry of Power, Government of India

The unit is awarded with National Level Green Chemistry Award for Innovation to use dual technology for the production of Mono Chloro Acetic Acid and Acetyl Chloride in a single Plant by the Govt of India

The site equipped with 17 MW power plants that full fill all the in-house power requirements.

The unit is awarded with Third prize in Safety Award for the year 2013 by State Safety Council Chandigarh

The unit is awarded with Star Export House award by Government of India

By incorporating these & other business strengths, IOLCP have boosted our

capabilities and planned for expansion of existing unit by addition some new products

and increasing the capacity of exiting product. IOLCP applied in MOEF&CC and

received TOR on 1st June 2018 (Letter No. J-11011/976/2008-IA-II(I)) for proposes

expansion of existing products and addition of new products from the capacity of

543.45 TPD to 671.95 TPD at Village Fatehgarh Channa, Mansa Road District

Barnala – 148101, Punjab.

No National Parks, Wildlife Sanctuaries, Tiger/ Elephant Reserves, Wildlife Corridors

etc. falls within 10 km radius from the plant site.

1.3. IMPORTANCE AND BENEFIT OF THE PROJECT

India is witnessing a steady rise in healthcare expenditure from US$ 76.1 per head in

2012 to US$ 118 per head in 2016. Still, India remains among the bottom five

countries with the lowest public health expenditure globally. A major chunk of the

population (nearly 40% of Indians) lives on less than US$ 1 per day, and most of them

have to pay out of their own pockets for medical services2. Out-of-pocket spending in

India is over four times higher than public spending on healthcare. Therefore, there is

a rising need for advanced drugs that will help people to recover quickly at lower

cost.The need of APIs is increasing every year due to continual growth of

pharmaceutical industry. IOLCP products cater to the key industrial sectors of

chemicals, Pharmaceutical & Packaging. Efficient teamwork & strong associations

showed the success. Through an unwavering focus on Quality, Commitment &

Delivery, IOLCP have charted the way to success in operations and have won the

admiration of the customers. This project is expected to partially fulfill the demand of

bulk drugs and APIs of pharmaceutical industries.

Market demand for chemicals and its intermediates is growing at a Compounded

Annual Growth Rate (CAGR) of 4-5% globally. The proposed project will contribute in

bridging this demand and supply gap by expansion of its chemicals production unit.



1.4. PURPOSE OF THE EIA STUDY

The objectives of the present EIA are to:

To identify and describe the elements of the community and environment likely to be affected by the proposed project, and/or likely to cause impacts upon both the natural and man-made environment.

To describe the proposed project and associated works together along with the requirements.

To identify and quantify any environmental impacts associated with the proposed project and recommend appropriate mitigation measures.

To identify existing landscape and visual quality in the study area so as to evaluate the landscape and visual impacts of the proposed project.

To propose mitigation measures to minimize pollution, environmental disturbance and nuisance during construction and operation of the proposed project.

To identify, assess and specify methods, measures and standards, to be included in the detailed design, construction and operation of the proposed project which are necessary to mitigate these impacts and reduce them to allowable levels within established standards/guidelines.

To identify and justify the need for environmental monitoring to define the scope of the requirements necessary. To ensure the implementation and the effectiveness of the environmental protection and pollution control measures adopted.

To identify constraints associated with the mitigation measures recommended in this EIA.

To identify any additional studies necessary to fulfil the objectives required for the EIA Study

1.5. PROJECT LOCATION

M/s IOL Chemicals & Pharmaceuticals Limited (IOLCP) is based at Village Fatehgarh

Channa on Mansa Road, Tehsil & District Barnala Punjab. It is spread over 62 acres.

Near the project site Trident groups are available as a textile unit, paper unit, sulphuric

acid plant The other unit is kanahayia solvex.The proposed site is at a distance of

about 1.45km, SE from village Fatehgarh Channa, State Highway 13 is at a distance

of .81 km NW in Direction. Nearest Railway station is Barnala railway station 8.69 km

from the project site and Chandigarh airport is approx. 130 km away in NE direction

from project site (aerial distance). No National Parks, Wildlife Sanctuaries, Tiger/

Elephant Reserves, Wildlife Corridors etc. falls within 10 km radius from the plant site.

The Plant boundary coordinates and project site location on Toposheet is shown in

Figure 1.1 and Figure 1.2.

The total investment is ~ Rs 205 crores

The capital investment towards environment management is estimated to be Rs.690

lacs and recurring cost will be Rs. 483 lacs.



Figure 1.1 : Plant coordinates



Figure 1.2 : Project Location (on Toposheet)



1.6. REGULATORY FRAMEWORK

Requirement of Environmental Clearance

Prior Environmental Clearance is required from concerned authorities for all projects and

activities mentioned in ―Schedule‖ as per Environmental Impact Assessment notification

dated September 14, 2006. The project comes under ―project and activity-5 (f) of

schedule.‖ Because site is not located in industrial area. Considering the products

portfolio, the proposed projects falls in ―Category A‖ of Schedule of the EIA notification

which requires Environmental Clearance (EC) from MoEF&CC, New Delhi.

IOLCP has commenced the process of obtaining required statutory permission from

concerned authorities. Details of permits and clearance applicable to this project along

with status are as under.

Table 1.1 : Details of permits and clearance applicable

S. No Permit / Clearance/Standards Proposed Project Existing Plant

1 No Objection Certificate /Consent to Establish from Punjab Pollution Control Board (PPCB)

Mandatory, shall be applied after obtained Environmental Clearance

Valid NOC from PPCB for existing plant is available with IOLCP

2 Factory License Valid Factory License is available with IOLCP

Valid Factory License is available with IOLCP

3 Water Permission Valid Surface water permission is available with IOLCP

Valid ground water permission is available with IOLCP

4

Consent to Operated under Air (Prevention and Control of Pollution) Act, 1981, Water (Prevention and Control of Pollution) Act,1974 and Hazardous Waste (Management, Handling and Trans boundary Movement) Rules 2016.

Mandatory, shall be applied after getting Environmental Clearance

Valid Consent from PPCB for existing plant available with IOLCP.

(Source: EQMS)

In addition to environmental regulatory compliance, other applicable statutory rules

and regulations including (but not limited to) are the following:

Permission for storage of hazardous Chemicals form Chief Controller of Explosive

(CCOE) Labour laws and Safety guidelines as per Labour Commissioner,

Government of Punjab.

Boiler Regulations as per Chief Inspector of Boilers, Government of Punjab

ESIC etc.

1.7. PUBLIC HEARING

As per Ministry of Environment and Forest, GOI, New Delhi vide its Notification No.

S.O.1533 dated September 14, 2006 and subsequent amendment thereof. A draft EIA

report has submitted (Prepared as per prescribe TOR) at Punjab Pollution Control

Board report. Further an advertisement was published in three prominent newspapers,



‗The Tribune‘, ‗Ajit‘ and ‗Spokesman‘ dated 25 Sep 2018. In the presence of ADC-

Barnala, Representative of Punjab Pollution Control Board, Patiala & Regional office

PPCB, Sangrur with near by public, Public Hearing was conducted on 26th Oct 2018

at Village Fatehgarh Channa, Mansa Road, Barnala, Punjab for the Proposed

Expansion of Chemicals and APIs production unit, from capacity of 543.45 TPD to

671.95 TPD by M/s IOL Chemicals & Pharmaceuticals Limited. which is coverd under

Category-A. Most of the issue raised during public hearing were related to

employment, CSR and clarity oriented related to environmental aspects and the

procedding are addressed in below Table The issues raised during the public hearing

with reply and public hearing minutes enclosed as Annexure VII.

Table 1.2 : Public hearing Queries with Complaince

S.

No.

Name &

Address of the

Person

Detail of Query/ Statement/

Information/ Clarification sought

by the person present in the

Public Hearing Meeting

Reply of the Query/

Statement/

Information/Clarification

given by the Project

Proponent

1. Sh. Narinder Pal

Singh :

Dhanaula,

District Barnala

He stated that whatever explained

about the project, pollution control

devices and other activities to be

carried out for the proposed

expansion project are seems to be

good. He further stated that

whatever explained and

commitment/promised made by the

industry should be fulfilled. He also

stated that the industry should plant

26,000 trees as explained and

committed by it and the trees

should be planted in their village

also. He requested that a water

cooler be provided in the school of

their village. He also stated that

there is unemployment in the State

and it is not possible for the Govt.

to provide Govt. jobs to

unemployed, as such, he requested

the company to provide

employment to the local people. He

also stated the company is giving

good salary in comparison to other

industries to its workers/staff. He

reiterated that whatever

commitments are made, the

industry should fulfill. He again said

that the employment should be

The representative of the

company informed that as

explained in the EIA report,

30,000 trees will be planted

and the care of the same will

be carried out for three years.

He also informed that they will

discuss the matter with

representatives of clubs and

village panchayats to provide

common land for planting trees

and the industry will care these

trees for 3 years. He also

informed that the employment

will be given the local people.

He further informed that the

company requires M. Sc. & B.

Sc candidates. The company

has recruited 300-400 persons

from different institutions. He

committed that the first

preference will be given to the

applicants of District Barnala.



given to the local residents. He

thanked the company for the

proposed expansion.

2. Sh. Samarjit

Singh : Member

Panchayat,

Dhaula, District

Barnala

He stated that whatever

commitments made by the industry,

the same should be fulfilled and the

trees should be planted. He also

stated that the company should

provide tree guards to care the

trees. He expressed happiness on

the proposed expansion of the

project. He further stated that on

the proposed expansion, direct and

indirect employment opportunities

will be generated for the local

people. He demanded that medical

camps be organized in the nearby

villages. He also demanded that

computers be provided to the Govt.

schools of the village.


industry informed that

providing tree guards is a good

suggestion and the same will

be adopted by the company.

The trees will be planted and

their care will also be taken for

three years. The company will

adopt nearby Govt. schools

and water coolers and

computers will be provided to

them.

3. Sh. Gurmit

Singh,

Councilor,

Handaya,

District Barnala

He stated that M/s Trident & IOL

are caring the environment. He

further stated that care of trees

should be done. The company

should care the health of the people

and they are expecting the same

from the company.


company informed that the

medical camps have been

organized by the company in

village Dhanaula, Fatehgarh

Chhanna and other villages.

He also informed that the

medical camps will also be

organized in future under the

CSR activities. He further

informed that now, the

company is profit making and

3% of the profit will be spent on

the CSR activities in the

nearby area.

4. Sh. Balwinder

Singh, R/o Billa

Khurd, District

Barnala

He expressed happiness over the

proposed expansion of the industry.

He stated that 7-8 persons of their

village are working in the company

and indirect people of the area are

getting employment from the

industry. The unemployment is a

big problem of the State, the Govt.

has also no solution of the same,

as such, company should provide


industry informed that the

industry is using huge quantity

of rice husk (about 6,000 TPA)

and other bio-mass as fuel in

the boiler, but the rice straw

directly cannot be used as fuel

in the boiler. The industry will

try to explore the solution of

rice straw to use as fuel in the



the employment to the local people.

The industry namely M/s Malwa

Cotton Spinning Mill is lying closed

since long, therefore, the persons

who were working there have lost

their jobs. He requested that the

company like IOL should be

established in the area, so that the

people of the area may get

employment from the same. He

demanded that the employment

should be given to the local people.

He informed that the standards of

farmers in the State are falling

down day by day. He further stated

that the industry should explore the

possibility of rice straw as fuel in

the industry, so that the problem of

burning of rice straw may reduce to

some extent in the area.

boiler.

5. Sh. Gurmel

Singh, Aarewala

R/o Handaya,

District Barnala

He stated that he is associated with

the industry since long time. He

wished that the industry may

flourish day-by-day. Now, the roads

have been made in the industry and

the industry and the industry is

growing day-by-day. No payment is

pending with the industry. Due to

the establishment of the industry,

20 persons are working in his

workshop (saw mill). He stated that

the preference should be given to

the local persons in the

employment.


industry reiterated that

preference will be given to the

local people. More than 70% of

the total staff/workers working

in the industry belong to the

local area.

6. Sh. Multi Singh,

R/o Kahne Ke,

District Barnala

He stated that he is a small farmer

and has very small land holding

and he is working as milkman. He

further stated that he is selling the

milk@ Rs. 50/- per liter to the staff

/workers of the industry due to

which he is getting more profit and

his living standard has been

upgraded. The nearby area has

developed due to this factory. He

requested that there is a heavy

traffic at the main gate of the


industry informed that they

have taken 10 acres of land

only for parking the vehicles

which comes to the industry for

any purpose. The parked

vehicles are allowed to enter

one by one so as to avoid

traffic congestion on the main

entrance gate of the industry.

He further informed that the

point raised by him has also



industry due to the parking of trucks

and tractor-trolleys, due to which

there are chances of accident. He

further stated that if any accident

took place near the industry, the

industry ambulance has helped the

victim to admit in the hospital. He

demanded that the employment

should be given to the local people.

been noted down and more

precautions/steps will be taken

to set right the said point.

7. Sh. Ranjit

Singh, R/o Kot

Duna village,

District Barnala

He stated that due to proposed

expansion, the people of the area

will get more employment

opportunities. The position of the

pond of their village was very bad

and the people of the village were

facing problem due to it. The

industry has got the pond cleaned

and solved their problem. 200-250

saples should be given to their

village. Due to the establishment of

the industry, the name of Barnala

district has come to lime light. The

industry has its own ambulance,

which they engaged to get the

person, who injured in accident,

admitted in the hospital. He

demanded that a staff bus be

provided to get the staff/workers

from their villages/homes

specifically in rainy days and in

winter season.


industry informed that the

buses have been engaged for

the purpose from Barnala and

Dhanaula. If possible, the

industry will try to extend the

rout of the same to get the

more workers. Safety of the

staff/workers is not only

important to the family

members of workers, but also

important to them. 250 saples

as demanded shall also be

provided to their village. The

representative of the industry

further informed that the

people who come to attend the

Public hearing meeting should

raise/suggest questions

regarding

pollution/environment of the

industry, so that they will be

able to improve the same.

8. Sh. Ram Singh,

R/o Village

Kureke Kalan,

District Barnala

How much of increase in the

pollution from the proposed

expansion and how the pollution

from the industry will be controlled?

He stated that thieves/anti social

elements are snatching money and

other valuable ornaments from the

workers who come back their

homes from the industry at night.

He demanded from the district

Administration that proper

arrangements may be made in this

regards.

The environmental consultant

of the industry informed that

the pollution control devices of

latest technology will be

provided to control the pollution

from the industry. There is

insignificant increase in the

pollution from the proposed

expansion (increased level of

PM 2.5 by 0.95 µg/Nm3, SOx

level by 0.61 µg/Nm3, NOx

level by 3.1 µg/Nm3). Regular

monitoring of the pollution

control devices will be done.



No wastewater will be

discharged outside the

premises of the industry and

the unit will be zero liquid

discharge.

9. Sh. Bhagwat

Singh, R/o

Handaya,

District Barnala

He stated that due to the

establishment of the industry, the

area upto 20 km has been

developed significantly.

He wanted to know:

What will be manufactured in the

expansion project? Whether any

distillery unit is being established in

the premises.

How the air pollution especially

smoke will be controlled, so as to

save the fields & homes from this

pollution?


industry informed that:-

No distillery plant is being

established. The industry has

proposed to expand its existing

unit for manufacturing bulk

drugs and Active

Pharmaceutical Ingredients

(APIs) like ibuprofen,

medicines for heart, diabetic

patients & other pain killers.

To control the air pollution,

Electrostatic Precipitator (ESP)

of latest technology will be

installed, the efficiency of

which is 99.9%, which will

arrest the smaller dust

particles. As such, there will be

no significant effect on the air

pollution from the project.

1.8. SCOPE & METHODOLOGY OF THE STUDY

This study is aimed at providing a deeper insight into the proposed project and its

various environmental components. The present study area for the environmental

assessment is within 10 km radius of the location of the project. The methodology

used for the study is given below:

Monitoring and collection of baseline data for various environmental

components as per the MoEFCC guidelines.

Identification and quantification of significant environmental impacts

due to the project and associated activities.

Evaluation of impacts due to proposed activities and preparation of

an environmental impact statement.

Preparation of appropriate Environmental Management Plan (EMP)

encompassing strategies for minimizing identified adverse impacts

along with budgetary provisions to be made by the project authorities

for implementation of mitigation measures.

Delineation of post Environmental Quality Monitoring Programmed (EQMP) along with

organizational setup required for monitoring the effectiveness of mitigation measures.



1.9. APPROVED TERMS OF REFERENCE FOR EIA STUDY BY EAC

Online document submitted on 19th April 2018 to Expert Appraisal Committee

(Industry-2). Standard Terms of Reference (TOR) was issued by MoEF&CC vide their

letter No: 11011/976/2008-IA-II(I) dated 1st June 2018 (Proposal No.

IA/PB/IND2/74654/2018) for preparation of EIA/EMP. The compliance status of

proposed TOR is as follow in subsection 1.8.1.

1.8.1 TOR Compliance Status

The TOR compliance status of the project has been presented in Table 1.2



Table 1.3 : Compliance Status of Terms of Reference

S.No. TOR Points Compliance

1. Executive Summary Ex. Summary in English is enclosed

2. Introduction

i. Details of the EIA Consultant including NABET accreditation

Nabet accreditation certificate enclosed as Annexure I

ii. Information about the project proponent

Detail of project proponent is given in Section 1.2.

iii. Importance and benefits of the project Project will be beneficial in govt‘s target of increase the production capacity, the importance and benefits is given in Section 1.3

3. Project Description

i. Cost of project and time of completion. Cost of the project is Rs 205 crores, the tentative time of completion is next 24 months

ii. Products with capacities for the proposed project.

Details of existing products and proposed expansion with CAS No, LC50 and LD50 is given in Section 2.5

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

Details of existing products and proposed expansion with CAS No, LC50 and LD50 are given in Section 2.5. Proposed expansion shall be carried out at existing premises, the land area breakup is given in Section 2.4. Copy of earlier EC is enclosed as Annexure II. Approval of change in product mix enclosed as Annexure III

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

Details of raw materials with CAS No, LC50 and LD50 and storage detail is given in Section 2.7. v. Other chemicals and materials required

with quantities and storage capacities

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

The detail of emissions, effluent and hazardous waste generation for the proposed expansion project is given in Section 2.8.8, 2.10 and 2.12 respectively

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

Utilities and manpower details is given in Section 2.8.

viii. Process description along with major equipment’s and machineries, process flow sheet (quantitative)from raw material to products to be provided

Process flow diagram of each products with material balance is given in Section 2.5. and Section 2.6 respectively

ix. Hazard identification and details of proposed safety systems.

Detail study carried as risk assessment, hence refer chapter 6

X. Expansion/modernization proposals:

c. Copy of all the Environmental Clearance(s) including Amendments thereto obtained for the project from

Its an expansion project the copy of Exisitng EC is enclosed as Annexure II Copy of approval for change in product



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 the ongoing / existing operation of the project from SPCB shall be attached with the EIA-EMP report.

mix is enclosed as Annexure III Copy of certified Compliance is enclosed as Annexure IV Copy of consent approval is enclosed as Annexure V

d. In case the existing project has not obtained environmental clearance, reasons for not taking EC under the provisions of the EIA Notification 1994 and/or 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.

Location of the project site is given in Section 1.5 and the Since expansion will be done at existing location, the need and justification of the proposed expansion project is given in Section 2.1

ii. A toposheet of the study area of radius of 10km 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)

Toposheet map of the study area of 10 km radius is given in Figure 1.2

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

The expansion is done within existing premises and justification of the project because of availability of facilities please refer Section 2.1

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

The boundary coordinates of the project site is given in Figure 1.1

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

Google map of the project site is given in Figure 3.3.

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.

The layout map indicating existing and proposed expansion is given in Figure 2.2. and Table 2.2

vii. Photographs of the proposed and Existing green belt photograph is given



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

in section 5.9.

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

Land use of the study area is given in Section 3.3.

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

Trident group is spread as Textile unit, paper unit and sulphuric acid manufacturing unit and Kanhiya Solvex Plant

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

The geological features of the study area is given in Section 3.2.3.

xi. Details of Drainage of the project up to 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 the 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)

There is no river with in study area, Drainage pattern of the study area is given in Section 3.2.2.

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.

Land is under possession of the industry

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

Not Applicable

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

Not Applicable

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

Not applicable

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

Not Applicable because no forest land involve.

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

Not Applicable

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 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-thereon.

There is no National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals within 10 km radius



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

Not applicable

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

Not Applicable

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 direction and rainfall.

Micro-meteorology of the study area is given in Section 3.4 and site specific of the study area is given in Section 3.4.1.

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 consider the pre-dominant wind direction, population zone and sensitive receptors including reserved forests.

AAQ data collected as per CPCB Norms at eight location considering the parameter PM10, PM2.5, SO2, NOx ,CO, VOCs and HCL.

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.

The baseline monitoring results are enclosed as Anneuxre IX.

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.

Surface water quality of the study area is given in Section 3.8.2.

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

NOT APPLICABLE

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

Ground water monitoring done at 8 locations, the analysis report is given in Section 3.8.1

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

Noise levels monitoring at 8 locations, please refer section 3.6

viii. Soil Characteristic as per CPCB guidelines.

Soil characteristics given in Section 3.9.

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.

Traffic study of the study area is given in Section 3.7.

x. Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area shall be given with special reference to

The biological environment of the study area is given in Section 3.10



rare, endemic and endangered species. If Schedule-I fauna are found within the study area, a Wildlife Conservation Plan shall be prepared and furnished.

xi. Socio-economic status of the study area. Demography of the study area is given in Section 3.11.

7. Impact and Environment Management Plan

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 Modelling 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 modelling 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.

The ambient air modelling of the emission from the proposed expansion is cover in Section 4.2.4 to 4.2.7. The air quality contours is given in Chapter 4

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

No discharge to water body. Waste

water is treated in ETP & send to

greenbelt development with in

premises; hence water quality

modeling is not required.

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.

The site in located near SH 13, from the proposed expansion project additional 10-15 truck/tankers are increases which will neither increase the load nor effect the existing road

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.

Complete scheme of effluent treatment with characteristics of inlet and outlet effluent is given in Section 2.8.8.

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

Stack emission details with controlling equipments is given in Section 2.10.

vi. Measures for fugitive emission control

vii. Details of hazardous waste generation and their storage, utilization and management. Copies of MOU regarding utilization of solid and hazardous waste in

Hazardous waste generation and their storage, utilization and management is given section 2.12 Copy of TSDF membership is enclosed as Annexure



cement plant shall also be included. EMP shall include the concept of waste-minimization, recycle/reuse/recover techniques, Energy conservation, and natural resource conservation.

VI

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

Detail action plan for fly ash management is given in Section 5.5

ix. Action 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.

Action plan for the green belt development plan is given in Section 5.9.

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

It‘s a chemical unit Rainwater harvesting in not possible within premises to avoid the ground water contamination, IOLCP already adopted 9 villages ponds for RWH in nearby areas.

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

The total investment is ~ Rs 205 crores. The capital investment towards environment management is estimated to be Rs.690 lacs and recurring cost will be Rs. 483 lacs.

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

Post-project environmental monitoring is given in Section 5.13.1.

xiii. Onsite and Offsite Disaster (Natural an Man-made) Preparedness and Emergency Management Plan including Risk Assessment and damage control. Disaster management plan should be linked with District disaster management plan.

A detailed risk assessment was carried -out, refer Chapter 6 of EIA report.

8. Occupational health

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

Adequate fund allocated for OHS, the detail given in Section 5.13.2. Facility for worker is given in Section 2.8.7.

ii. Details of exposure specific health status evaluation of worker. If the workers' health is being evaluated by pre-designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far & Near vision, color vision and any other ocular defect) ECG, 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,

The health checkup of all employees was carried out on annual basis same will be followed for proposed expansion project. The health report of the workers for existing unit are enclosed as Annexure X.



sex, duration of exposure and department wise.

iii. 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,

Adequate safety measures already taken and also propose safety measure for expansion unit, refer section 6.25

iv. Annual report of health status of workers with special reference to Occupational Health and Safety.

Annual report of health status of workers are enclosed as Annexure X

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.

The environmental management cell with respective responsibility is given in Section 5.12.

ii. Does the Environment Policy prescribe for standard operating 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.

Not applicable

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.

The environmental management cell with respective responsibility is given in Section 5.13.

iv. Does the company have system of reporting of non-compliances / 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

None, non-compliance / no violations reported till date.

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

Details of Facilities for the workers is given in Section 2.8.7.

11. Enterprise Social Commitment (ESC)

Adequate funds (at least 2.5 % of the project cost) shall be earmarked for Socio-economic development activities need to be elaborated upon.

Adequate fund allocated refer section 2.16.

12. Any litigation pending against the project and/or any direction/order passed by any Court of 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,

None



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

SPECIFIC TERMS OF REFERENCE

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

The solvent recovery plan is reflected in section 2.9

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

The emission from the process stack with control measures is given in Section 2.10

3. Ambient air quality data should include VOC , SO2 and NOx, other process-specific pollutants*like including NH3*, chlorine*, HCl*, HBr*, H2S*, HF*,etc.,(*-as applicable)

The ambient air quality data details is given in Section 3.5

4. Work zone monitoring arrangements for hazardous chemicals.

Covered in Risk assessment chapter

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

No wastewater will be discharged outside of the premises. Effluent generated from process, utilities and sewage which will be treated through ETP/MEE followed by ATFD and the treated water will be send for greenbelt

6. Action plan for odor control to be submitted. Section 5.4.1.

7. A copy of the Memorandum of Understanding signed with cement manufacturers indicating clearly that they co-process organic solid/hazardous waste generated, in case waste is proposed to be used for this purpose.

The copy of TSDF membership is enclosed as Annexure VI

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

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

Section 2.8.9.

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

MSDS of all the raw material is available.

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

The copy of TSDF membership is enclosed as Annexure VI

12. Details of incinerator/s (if any) if to be installed.

Not Applicable

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

Chapter 6

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

Refer Section 6.23

(Source: Standard TOR Issued by MoEF&CC)

1.10. STRUCTURE OF THE REPORT



This EIA report has been prepared on the basis of available on-site primary data

(survey/ monitoring) and secondary/literature data. The EIA report contains project

features, baseline environmental setup, assessment of environmental impacts, and

formulation of mitigation measures, environmental management and monitoring plan

with risk & disaster management plan.

The report would include 9 Chapters excluding Executive Summary, which is included

at the beginning of the report. The structure of the EIA Report with necessary tables,

drawings and annexure is as follows:

Chapter 1:Introduction

This chapter provides background information on need of project, need of EIA study

and brief of the project. The scope and EIA methodology adopted in preparation of EIA

report have also been described in this Chapter. It also covers the identification of

project & project proponent, brief description of nature, size, location of the project and

its importance to the country and the region. Scope of the study details about the

regulatory scoping carried out as per the generic structure given in the EIA

Notification, 2006.

Chapter 2: Project Description

This chapter deals with the project details of the proposed Chemicals

(Pharmaceuticals) Manufacturing Plant, with type of project, need for the project,

location, size & magnitude of operation including associated activities required by and

for the project, proposed schedule for approval and implementation, including

technical details of raw material, quality and quantity etc.

Chapter 3: Description of Environment

This chapter presents the existing environmental status of the study area around the

proposed project including topography, drainage pattern, water environment,

geological, climate, transport system, land use, flora & fauna, socio-economic aspects,

basic amenities etc. Environmental assessment of the proposed project site in regard

to its capability to receive the proposed new development is also discussed in this

Chapter.

Chapter 4: Anticipated Environmental Impacts and Mitigation Measures

This chapter describes the overall impacts of the proposed project activities and

underscores the areas of concern, which need mitigation measures. It predicts the

overall impact of the proposed project on different components of the environment viz.

air, water, land, noise, biological, and socio-economic.

Chapter 5: Environmental Management Plan

This chapter details the inferences drawn from the environmental impact assessment

exercise. It describes the overall impacts of the proposed activities during construction

and operation phases and underscores the areas of concern, which need mitigation

measures. It also provides mitigation and control measures for environmental

management plan (EMP) for minimizing the negative environmental impacts and to

strengthening the positive environmental impacts of the proposed project. Technical

aspects of monitoring the effectiveness of mitigation measures have been given in this

Chapter also.



Chapter 6: Risk Assessment & Disaster Management Plan

This chapter deals with the risk assessment carried out for the proposed Synthetic

Organic Chemicals manufacturing plant and disaster management plan.

Chapter 7: Summary & Conclusion

This chapter provides the summary and conclusions of the EIA study of the proposed

project with overall justification for implementation of the project and also explanation

of how, adverse effects will be mitigated. This chapter also includes the conclusions of

the Public Hearing.

Chapter 8: Disclosure of Consultants Engaged

This chapter provides the disclosure of consultants engaged to carry out the EIA study

along with other additional studies.

CHAPTER 2. PROJECT DESCRIPTION



2.1. NEED AND JUSTIFICATION OF THE PROJECT

Need of APIs is increasing every year due to continual growth of pharmaceutical industry.

This project is expected to contribute in partially fulfilling the demand of APIs for

pharmaceutical industries within Punjab rest of India. State Highway 13 is at .81 km NW in

Direction. Nearest Railway station is Barnala railway station 8.69 km from the project site and

which is advantageous in terms of transportation of raw materials as well as finished goods.

Following are the major factors justify the project location.

Availability of land in the existing premises

Site is well connected by road and rail

Availability of power and water

Availability of skilled manpower

Availability of nearest port

The site is well connected by road and rail to the rest of India.

2.2. SITE DETAILS AND LOCATION

i. Site Location

The propoed project is spread in 62 acres. The salient feature of the site is shown in

Table 2.1.

Table 2.1 : Salient features

S.NO Particulars Description

1. Products capacity 543.45 TPD to 671.95 TPD (approx 672 TPD).

2. Nearest Highway SH-13,0.81km, NW

3. Nearest Railway Station Barnala Railway Station,8.69km, NE

4. Nearest Village Fatehgarh Channa

5. Nearest Airport Chandigarh Airport,130km, NE

6. Total Area 62 acres

7. Green Belt 30 acres

8. Process / Drinking Water

Management (Source & Supply

of water)

Existing: 900 KLD (Source Ground water)

For Expansion: 900 KLD (Source Surface water)

Total water requirement: 1800 KLD

9. Industrial Waste Management. Send to TSDF site

10. Power Requirement & Supply /

source.

17 MW, In house, Cogeneration Plant

11. Manpower Existing: 1200

For Expansion: 650

Total Manpower: 1850

(Source: Site Visit/Secondary Sources)

This chapter deals with the brief details of the establishment of new proposed bulk drug

project; Location Consideration, Technology Description, Raw material Requirement and

its source, Process flow diagram, Environmental aspects etc.

EQMS India Pvt. Ltd. Document No. IOL/EIA/01 Issue No. 01 R 00 Page 35 of 357

Figure 2.1 : Project Location Map

EIA/EMP Report for expansion of APIs and Bulk drug production unit


2.3. Approach to Site

The proposed site is at a distance of about 1.45km, SE from village Fatehgarh Channa,

State Highway 13 is at a distance of .81 km NW in Direction. Nearest Railway station is

Barnala railway station 8.69 km from the project site and Chandigarh airport is approx. 130

km away in NE direction from project site (aerial distance).

2.4. LAND REQUIREMENT

The proposed project having total plot area around 250905 SQM (62 acres) situated at

Village Fatehgarh Channa on Mansa Road, Tehsil & District Barnala Punjab.

Table 2.2 : Land Distribution at site

S. No. Area Description Existing After Proposed

Expansion

Remarks

(Sq.mtr) (Sq.mtr)

1 Production plants including

ware house, utilities

48863.42 70952.42

2 Administration, QC, R&D,

HSE, Security and welfare

facilities

2217.97 2268

3 Open Areas, Roads,

Pathway & Auxiliary

56645.57 53763.53 Open area to

be used for

production

blocks , Future

Expansion etc

6 Scrap yards 1765.45 1765.45

7 Green belt/Plantation 97124.8 121404.8

Total 206617.21 250154.2 (61.84

acres or Approx

62 acres)

(Source:IOLCP)

Site layout is shown in Figure 2.2.



(Source: IOLCP)

Figure 2.2 : Site Layout



2.5. PRODUCTS WITH CAPACITIES FOR THE PROPOSED PROJECTS


hence the capacity increases from 543.45 TPD to 671.95TPD for the manufacturing of bulk drug

and API drugs production unit. IOLCP has applied for TOR in 19 April 2018 and Standard TOR

has been issued on 1st June 2018.

Table 2.3 : List of Products

S.No

Name of the products LD50 CAS No Existing Qty (TPD) as per EC F.No. J-11011/976/2008- IA II (I) dated 24.08.2009

Product mix ( as per SPCB letter No EE/Mega/2018/4859( TPD)

Proposed Products ( TPD )

Total Proposed Qty (TPD)

1 Acetic Acid Inhalation, mouse: LC50 = 5620

ppm/1H. Oral, rat: LD50 = 3310 mg/kg. Skin, rabbit: LD50 =

1060 mg/kg

64-19-7 300 0 0 0

2 Ethyl Acetate LD50 rat: > 2,000 mg/kg

141-78-6 150 300 0 300

3 Acetic Anhydride 636 mg/kg [Rat]. 740 mg/kg [Mouse]. 495 mg/kg [Guinea

pig].

108-24-7 70 70 0 70

4 Ibuprofen 636 mg/kg [Rat]. 740 mg/kg [Mouse]. 495 mg/kg [Guinea

pig].

15687-27-1

20 29 16 45

5 Monochloroacetic Acid Inhalation, rat: LC50 = 180 mg/m3;

Oral, rat: LD50 = 55 mg/kg;

. Dermal LD50 rat:

145 mg/kg (ACGIH). Dermal

LD50 rabbit: 177.8 mg/kg

79-11-8 40 40 0 40

6 Acetyl Chloride LD50 Oral - rat - 910 mg/kg

79-04-9 32 32 0 32

7 Iso Butyl benzene Dermal LD50 > 2000 mg/kg ( Rat )

538-93-2 40 40 20 60

8 Rabiprazole Sodium Single oral doses of rabeprazole at 786

mg/kg and 1024 mg/kg were

lethal to mice and rats, respectively.

117976-90-6

2 0 0 0

9 Diclofenac Sodium Rat Oral LD 50 53-77 mg/kg

15307-79-6

3.5 3.5 3.5 7

10 Metformin Hydrochloride Oral LD50 (rat): 1 g/kg; Oral LD50 (mouse): 1,450

mg/kg; Subcutaneous

1115-70-4

0 10 30 40



LD50 (rat): 300 mg/kg;

Subcutaneous LD50 (mouse): 225 mg/kg; Oral LD50 (rabbit):350 mg/kg;

11 Fenofibrate Oral LD50 (rat): >2 gm/kg; Oral LD50

(mouse) 1600 mg/kg;

49562-28-9

0 0.25 0.5 0.75

12 Clopidogrel Bisulphate Oral Rat 1914 mg/kg 120202-66-6

0 0.5 0.5 1

13 Amlodipine Mouse Oral Acute 37 mg/kg

Rat 393 mg/kg

111470-99-6

0 0.25 0 0.25

14 Lamotrigine Oral LD50 (rat): 205 mg/kg; Oral

LD50 (mouse): 245 mg/kg;

84057-84-

1

0 0.1 0 0.1

15 Phineramine Base LD50 Mouse Oral 268 mg/kg

Rat 520 mg/kg

86-21-5 0 0.1 0 0.1

16 Ibuprofen Lysinate LD50 (rat): 841

mg/kg

57469-77-9

0 0.5 0 0.5

17 Ursodeoxycholic Acid LD50 Oral - rat - 4,600 mg/kg

128-13-2 0 0.25 0 0.25

18 Quetiapine Rat Oral 250 mg/kg/day

111974-72-2

0 0 3 3

19 Dex - Ibuprofen Oral LD50 value in

rats is 636 mg/kg

51146-56-6

0 0 0.5 0.5

20 Gabapentene Mouse Oral LD50 > 5000 mg/kg

Rat Oral LD50 > 5000 mg/kg

60142-96-3

0 0 5 5

21 Pentaprazole Rat Oral LD 50 747 mg/kg

164579-32-2

0 0 1 1

22 losartan Potassium Mouse Oral Minimum Lethal

Dose 1000 mg/kg Rat Oral Minimum Lethal Dose 2000

mg/kg

124750-99-8

0 0 1 1

23 Fexofenadine 20 mg/kg (guinea pig)

5 mg/kg (mouse)

153439-40-8

0 0 0.5 0.5

24 Ibuprofen Sodium LD50 rat : 636 mg/kg

31121-93-4

0 0 2 2

25 CMIC Chloride 25629-50-9

0 0 2 2

26 DCMIC Chloride 4462-55-9

0 0 0.5 0.5

27 FCMIC Chloride 69399-79-7

0 0.5 0.5

28 MIBT 5160-99-6

0 0 10 10

29 Propyl Acetate Acute oral toxicity (LD50): 6640 mg/kg

[Rabbit].

109-60-4 0 0 20 20



30s Intermediate Products

1) HEEP 13349-82-1

0 0 1 1

2) Methyl-2-amino-3-chloropropionate HCl

33646-31-0

0 0 0.5 0.5

3) 2-(2-(Aminothiazole-4-yl)-2-[2-(terbutoxycarbonyl) isopropoxyimino] acetic acid (ATTBA) Ceftazidime intermediate

86299-47-0

0 0 0.25 0.25

4) 2-chloro-3-cyanopyridine Mirtazipine intermediate

6602-54-6

0 0 0.25 0.25

5) 4'-methyl-2-cyanobiphenyl (OTBN)

114772-53-1

0 0 1 1

6) m-Phenoxybenzaldehyde 39515-51-0

0 0 2 2

7) 4-aminobenzamide 2835-68-9

0 0 2 2

8) p-nitrobenzoyl chloride Oral, mouse: LD50 = 3440 mg/kg;

Oral, rabbit: LD50 = 4750 mg/kg;

122-04-3 0 0 3 3

9) Vanillin Oral, mouse: LD50 = 1480 mg/kg;

Oral, rat: LD50 = 1580 mg/kg;

121-33-5 0 0 2 2

31 Cogeneration 17 17 17

Total 674.5 543.45 128.5 671.95

(Source: PFR)

All the products are not manufactured at a time. The likely production capacities of the products

will depend upon market demand but limited to the sanctioned capacity as mentioned above.

2.6. MANUFACTURING PROCESS

2.6.1. Manufacturing Process of Ethyl Acetate

The basic raw material for the production of Ethyl Acetate is Ethyl Alcohol and Acetic Acid.

In order to have best quality Ethyl Acetate product, Ethyl Alcohol is firstly passed through a shell

and tube heat exchanger and then through a distillation column, so as to separate smell- causing

molasses from Alcohol. The distilled alcohol vapors are sent to the reaction kettle where acetic

acid is also added.

Ethyl Alcohol & Acetic Acid react together to produce Ethyl Acetate. As Ethyl Acetate produced is

of 99.9 %

The reaction is as follows:-

C2H5OH + CH3COOH ----------------------> CH3COOC2H5 + H2O Alcohol Acetic Acid 102- 105

0 C Ethyl Acetate Water

The Ethyl Alcohol & Acetic Acid are mixed in the Reaction Kettle. In the kettle, temperature of

102 to 1050 C and pressure of 0.1 to 0.15 kg/cm2 is maintained. The reaction is endothermic and

in order to provide required heat of reaction, heat is supplied by means of the reboilers attached

to the reaction kettle. The vapors from the top of the Reaction Kettle are sent to Ethyl Column



No. 1. The vapors coming from the top of the column are condensed in condenser No. 1 and 2

with the help of cooling water and then passed through another cooler. The condensed material

is then sent to the Decanter-1. Here two layers get formed in which the top layer is of Crude Ethyl

Acetate and the bottom layer consists of Alcohol, Water & Ester. A portion of the top layer is

recycled back to the Reaction column and the rest is fed to the Ethyl Column No. 2 where again

same procedure is repeated.

Now, the top layer of decanter of Column No. 1 and 2 are sent to Distillation Column, which has

an inbuilt Reboiler so as to provide proper heat for distillation. In the Distillation Column Ethyl

Acetate vapors are generated which are condensed and cooled and the finished Ethyl Acetate is

then diverted to the Daily Storage Tanks (DST) .

The vapors from the top of the Distillation Column are condensed in Condenser 1 and 2 and then

cooled in a Cooler. The cooled material is then taken in the Decanter – 2. Here also the two

layers get formed. The top layer is of Crude Ethyl Acetate and the bottom is of Alcohol, Water &

Ester. The top layer is recycled back to the Distillation Column and some part of it is send to the

Reaction Kettle. The bottom layers of the Decanters of Column No. 1 and 2 along with decanter

of distillation column are fed to the Recovery Column where Ester and Alcohol are recovered and

the water is drained out after recovering its heat in a Plate Type heat Exchanger installed at the

drain point of the recovery column.



Figure 2.3 : Process flow diagram

Mass balance of Ethyl Acetate

Input Output

Name of Material Unit Qty Name of Material

Unit Qty

Ethyl Alcohol MT 156 Ethyl Acetate MT 300.00

Acetic Acid MT 204.00 Water MT 174.37

Water for washing MT 100.00

Water from Alcohol MT 14.37

Total 474.37 Total 474.37

2.6.2. Manufacturing Process of Acetic Anhydride

Acetic Anhydride plant uses the Acetic Acid. Acetic Acid after preheating is fed into the

vaporizer where Acetic Acid is vaporized and the vapors of Acetic Acid are fed in the the

Ketene furnace where Acetic Acid is dehydrated into ketene at around 700-750 deg C. The

following reaction takes place in the furnace:



700-750 deg. C

CH3COOH ------------------------------------------------->CH2CO + H2O

AceticAcid Ketene Watervapors

The outlet of ketene goes to the gas coolers where Acetic Acid vapors and water are

condensed. The condensate is then fed to the pump vessel. The ketene gas is absorbed by

the Acetic Acid to form Acetic Anhydride by the following reaction:

CH2C0* + CH3COOH ------------------------------------>C4H6O3

Ketene AceticAcid Acetic AnhydrideGas

Scrubbers are four in numbers and their relative Equipment numbering is Scrubber – 110 ,

114 , 117 , 118. Packing are provided in all the Scrubbers as that of 20 mm O.D Rasching

Rings. The first Scrubber is 110 in which the feed is of the Ketene Gas from the top of the

K.O.P.-1. From the top, in the Scrubber – 110, the Liquid stream from the bottom overflow of

Scrubber – 114 is fed as the Absorbent. The reaction takes place between the Ketene Gas &

the Acetic Acid so as to form the Product Acetic Anhydride. 70 – 75 % of the total Ketene

Gas gets reacted & the rest comes out from the top of the Scrubber – 110 & becomes feed

for the Scrubber – 114. In Scrubber – 110 the liquid keeps on collecting at the bottom, which

contains the Acetic Anhydride that has formed. This liquid always remains in circulation at

the Scrubber through the Inter Cooler – 112 the Centrifugal Circulation Pump 221 & 222.

When the Liquid level reaches certain specified mark, it gets automatically transferred to the

Scrubber – 117 through the Inter Cooler – 132 by the Centrifugal Circulation Pumps 221 &

222 & acts as the Absorption media there. In Scrubber – 114 the remaining of the reaction

between the Ketene Gas & the Acetic Acid is completed. The Absorbent is the fresh feed of

the Acetic Acid that is supplied from the Acetic Acid Tanks by means of Centrifugal Pumps

231&232 through the Inter Cooler – 116. Here also in the same manner there is a collection

of the liquid at the bottom of the Scrubber. When the required level is achieved, the material

gets transferred to the Scrubber – 110 & is the Absorption media of that. After first two

Scrubbers i.e 110 & 114 the reaction gets completed between the Ketene Gas & Acetic Acid.

Now the gas, which escapes the top of the Scrubber – 114, comes to the Scrubber – 117.

Here the main purpose is to improve the color of the product Acetic Anhydride. The

unabsorbed gases are then send to the Scrubber – 118 from the top of the Scrubber – 117.

Also from the bottom of the Scrubber – 117 one stream is fed to the Distillation Column- 120

Of Acetic Anhydride. This stream contains the entire Acetic Anhydride that has formed in the

Scrubbers.In Scrubber–118 there is the feed of the D.A (Dilute Acetic Acid) from the bottom

of the K.O.P – 2 by the centrifugal circulation pump, which is the Absorption media of that. At

the top of the Scrubber - 118 we have the connection of The System which provides the

vacuum & hence the means for the conveying of gases through the packing. In Scrubber –

118 no Chemical reaction takes place. Now in the Distilation Column 120 the purpose is of to

recover the product Acetic Anhydride. The column is a Bubble Cap Tray Column and the top

product is Acetic anhydride, which is then sent to DST for daily storage.



Figure 2.4 : Process flow diagram of Acetic Anhydride

Material Balance

Input Output

Name of Material Unit Qty Name of Material Unit Qty

Acetic Acid MT 82.82 Acetic Anhydride MT 70.00

Water MT 10.00 Water MT 22.82




2.6.3. Manufacturing process of Mono Chloro Acetic acid & acetyl chloride

Mono Chloro Acetic acid & acetyl chloride are manufactured together in a single reaction

column.

Acetic anhydride is fed on the top of reaction column. Chlorine gas purged from the bottom

of the column through sparger. Acetic anhydride reacts with HCL gas & produce acetic acid &

acetyl chloride. This acetic acid further reacts with chlorine gas in the presence of acetyl

chloride & gives Mono Chloro Acetic acid & Hcl gas which reacts with acetic anhydride as

mentioned above. The reaction mixture circulated in the reaction column so that above

reactions takes place,circulation in reaction column done by means of the centrifugal

pumps. . The Hcl gas generated from the reaction reacts with the acetic anhydride &

produce acetyl chloride & acetic acid. This acetic acid produce in the reaction reacts with

chlorine & produce Mono Chloro Acetic acid & HCL gas. Acetyl chloride produce by reaction

of acetic anhydride & Hcl gas acts as a catalyst for the Mono Chloro Acetic acid reaction.

The acetyl chloride molecule attaches with the chlorine atom & produces the chloroacetyl ion

which reacts with acetic acid & produces the Mono Chloro Acetic acid. Acetyl chloride

remainsunreacted.

The both combination of reactions takes place in single reaction column.

Room temp.

(CH3COO)2+HCL CH3COOH +CH3COCl Δ H = -IVE

(SLIGHTLY)

95 deg c

CH3COOH+Cl2 ClCH2COOH +Hcl Δ H = +IVE

As given above, for both reactions the temperature & pressure conditions are different.

In first reaction the acetic anhydride reacts with HCL gas at room temperature & this

reaction is slightly exothermic in nature. Whereas the second reaction of acetic acid with

chlorine occurs at high temperature of 95-100 deg c & this reaction is slightly endothermic

in nature.






Material BalanceMono Chloro Acetic Acid

Input Output

Name of Material Unit Qty Name of

Material

Unit Qty

Acetic Acid MT 25.39 Mono Chloro

Acetic Acid

MT 40.00

Chlorine MT 30.05 Water MT 10.0

Water MT 10.0 Hydrochloric

Acid

MT 15.44

Total 65.44 65.44

Material balance of Acetyl Chloride

Input Output


Material

Unit Qty

Acetic Anhydride MT 41.57 Acetic Acid MT 24.45

HCL MT 14.88 Acetyl

Chloride

MT 32.0


Total 66.45 66.45

2.6.4. Manufacturing process of Iso Butyl benzene

Production of isobutyl benzene involves the Alkylation‘s of toluene with propylene in the

presence of a sodium/potassium alloy (NaK2). A mixture of isobutyl benzene (IBB) and n-butyl

benzene (NBB) are produced with IBB predominating. Toluene is mixed with catalyst and

heated to its boiling point and propylene gas is bubbled. The temperature is maintained at

elevated temperature and higher pressure. The reaction will be start at boiling temperatures.

The converted mixture of products is filtered to recover the catalyst.

.The Nitrogen required for blanking purpose is generated in our own Nitrogen generation plant.

This Nitrogen is also used for purging of vessels as and when required. Recovered Potassium

carbonate sold out.



Figure 2.6 : Process flow diagram of Iso Butyl benzene

Material Balance of Iso Butyl benzene

Input Output


Toluene MT 41.18 Iso Butyl Benzene MT 60.00

Propylene MT 18.82 Water MT 45.0

Water MT 45.0

Total 105.00 105.00

2.6.5. Manufacturing process of Diclofenac Sodium

The process involves firstly, preparation of Mono methyl chloro acetate in GL reactor by reaction

between methanol & monochloroacetic acid, Then in SS reactor, 2,6-Dichlorophenol, potassium

carbonate & toluene is charged and then Mono methyl chloro acetate is added slowly at controlled



temp. and then the reaction mass is worked up to give 2,6 -dichloro-N-phenylbenzeneamine as

Intermediate which is separated & then reacted with Chloro acetyl chloride in a GL reactor & then

worked up to give 2- chloro-N-(2,6-dichlorophenol)-N-phenylacetamide as Intermediate, which is

separated & dried. This is then further reacted with Aluminium chloride, anhydrous in a GL reactor &

worked up to give 1-(2-6-dichlorophenyl) indolin-2-one as Intermediate, which is separated & then

hydrolysed in alkaline medium to give Diclofenac Sodium, which is suitably purified to give Diclofenac

sodium. Poly Aluminium chloride to be sale to paper industries for paper sizing

Figure 2.7 :Process flow diagram of Diclofenac Sodium

Material balance of Diclofenac Sodium

Input Output

Stage-1

Name of Material Unit Qty Name of Unit Qty



Material

Mono Methyl Chloro Acetate

MT 2.41 Methyl 2-(2,6-dichlorophenoxy) acetate

MT 5.17

2,6-dichlorophenol MT 3.62 HCL MT 0.803

Water MT 10 Water MT 10.057

Total 16.03 16.03

Stage-2


Unit Qty

Aniline MT 2.07 2,6 dichloro-N-Phenylbenzene

MT 5.2371

Methyl 2-(2,6-dichlorophenoxy) acetate

MT 5.17 Methanol MT 0.7050

Water MT 10.0 Carbon Dioxide

MT 0.9680

Sodium Methoxide MT 1.20 Sodium Ethoxide

MT 1.4960

Water MT 10.0339

Total MT 18.44 Total MT 18.44

Stage-3


Unit Qty

2,6 dichloro-N-Phenylbenzene

MT 5.2371 (2-Chloro-N-(2,6dichlorophenylacetamide)

MT 6.9201

Chloro Acetyl Chloride

MT 2.51 HCL MT 0.803


Total 17.7471 17.7471

Stage-4


Unit Qty

(2-Chloro-N-(2,6dichlorophenylacetamide)

MT 6.9201 (1-(2,6-dichlorophenyl)indolin-2-one)

MT 6.12

Aluminium Chloride MT 2.96 Hydrochloric Acid

MT 3.212

Water MT 21.20 Aluminium Hydroxide

MT 1.716

Water MT 20.0321


Stage 5




Unit Qty

(1-(2,6-dichlorophenyl)indolin-2-one)

MT 6.12 Diclofenac Sodium

MT 7.00

Sodium Hydroxide MT 0.889 Water MT 20.009

Water MT 20.0

Total MT 27.009 Total 27.009

2.6.6. Manufacturing process of Metformin Hydrochloride

N-Butanol is charged to a reaction vessel at room temperature followed by addition of Dimethyl amine

Hydrochloride. Reaction mass is heated & followed by addition of Dicyanodiamide under heating.

Reaction mass is refluxed till completion. Reaction mass is cooled & extracted with water. Layers are

separated, from which organic layer i.e O-xylene layer is reused as such in next batch & Aq. layer is

distilled off under vacuum. Reaction mass is cooled & solid is filtered & dried as Metformin

Hydrochloride.

Figure 2.8 : Process flow diagram of Metformin Hydrochloride

Material balance of Metformin Hydrochloride

Stage-1


Material

Unit Qty

Dicyandiamide MT 20.30 Metformin

Hydrochloride

MT 40

Dimethyl amine

Hydrochloride

MT 19.89 Water MT 15.19

Water for washing MT 15.00




2.6.7. Manufacturing process of Fenofibrate

Stage-01:

4-chloro-4-hydroxy benzophenone is heated with NaOH & acetone, chloroform. After

completion of reaction, mass is distilled off followed by addition of water. pH of mass is

acidified & material is filtered. Wet cake is recrystallized using ethyl acetate & water to give

stage-01 i.e fenofibric acid.

Stage-02:

Fenofibric acid is mixed with IPA & Sulfuric acid. Reaction mass is refluxed & after completion

of reaction water & Chloroform is added. pH of reaction mass is basified with aq. NaOH

solution. Layer is separated & Chloroform layer is distilled off. Material is crystallized with IPA.

Solid is filtered & recrystallized with IPA to give pure Fenofibrate.

Figure 2.9 : Process flow diagram of Fenofibrate

Material balance of Fenofibrate

Stage-1


Material

Unit Qty

(4-chlorophenyl)(4-

hydroxy

phenyl)methanone

MT 0.4839 2-(4-[4-

chlorophenyl)

carbonyl]phen

oxy]-2-

MT 0.6630



methylpropan

oic acid

Sodium Hydroxide MT 0.252 Sodium

Chloride

MT 0.3651

Chloroform MT 0.247 Rxn Water MT 0.075

Acetone MT 0.120 Water MT 6.000

Water MT 6.000


Stage-2


Material

Unit Qty

2-(4-[4-

chlorophenyl)carbo

nyl]phenoxy]-2-

methylpropanoic

acid

MT 0.6630 Propan-2-yl 2-

(4-[(4-

chlorophenyl)

carbonyl]phen

oxy)-2-

methylpropan

oate (

Fenofibrate)

MT 0.7500

IPA MT 0.1260

water MT 6.0000 water MT 6.039


2.6.8. Manufacturing process of Clopidogrel Bisulphate

Stage-I: CPG methyl ester

2-Chloro phenyl glycine esterified with sulfuric acid and methanol at high temperature. After

completion of reaction distill methanol and isolated oil by adjusting pH of reaction mass. MDC

layer distilled to get oily mass of stage-1.Ammonium sulphate generated as by product which

will be sold out to users.

Stage-II: Tartrate salt

CPG ester (Stage-1) was added in a solution of methanol acetone mixture and L (+) tartaric

acid at ambient temperature. Solution was stirred followed by seeding of tartarate salt cooled to

low temperature and filtered. Wet cake was dried at high temperature to get tartarate salt.

Stage-III: Tosylate

Thiophene- 2- ethanol was tosylated with para toluene sulfonyl chloride and sodium hydroxide

solution at ambient temperature in presence of phase transfer catalyst. Tosylate was extracted

with Toluene and used as such in next step.

Stage-IVA: Chiral base



Tartrate salt was converted into chiral base by adjusting pH with ammonia solution. Base was

extracted with Toluene and used as such in next step.

Stage-IVB: Couple Amine Hydrochloride

Organic layer of chiral base and tosylate was coupled by using DPHOP as base in presence of

phase transfer catalyst at high temperature. After completion of reaction was worked up and

free base formed. Base converted to hydrochloride salt with IPA.HCl. Hydrochloride salt was

centrifuged and washed with toluene and dried.

Stage-V: Clopidogrel Bisulphate

Reaction of couple amine hydrochloride with paraformaldehyde followed by cyclization in acidic

medium to give Clopidogrel base thus obtained free base treated with sulfuric acid in acetone to

afford Clopidogrel bisulphate.



Figure 2.10 : Process flow diagram of Clopidogrel Bisulphate



Material balance of Clopidogrel Bisulphate

Stage-1


2-Chloro Phenyl Glycine MT 0.4421 Methyl 2- amino-2-(2-

Chlorophenyl)acetate

MT 0.4755

Sulphuric Acid MT 0.2359 Ammonium Sulphate MT 0.3146

Methanol MT 0.1525 Methanol MT 0.076

Ammonium Hydroxide MT 0.1685 Water MT 2.1329

Water MT 2.000


Stage-2


Methyl 2- amino-2-(2-

Chlorophenyl)acetate

MT 0.4755 (R)-methyl 2-amino-2-(2-

chlorophenyl)acetate

(2R,3R)-2,3-

dihydroxysuccinate

MT 0.8331

Tartaric Acid MT 0.3611



Stage-3


2-(thiophen-2-yl)ethanol MT 0.3050 2-(thiophen-2-yl)ethyl 4-

methylbenzenesulfonate

MT 0.6722

4-methylbenzene-1-

sulfonyl chloride

MT 0.4586 Sodium Chloride MT 0.1394

Sodium Hydroxide MT 0.096 water MT 2.0480

water MT 2.0000


Stage-IVA

(R)-methyl 2-amino-2-(2-


(2R,3R)-2,3-dihydroxy

succinate

MT 0.8331 (R)-methyl 2-amino-2-(2-


MT 0.4755

Ammonium Hydroxide MT 0.1685 Tartaric Acid Ammonium

Salt

MT 0.4386



Stage-IVB

(R)-methyl 2-amino-2-(2- MT 0.4755 (S)-methyl 2-(2- MT 0.8247



chlorophenyl)acetate chlorophenyl)-2-((2-

(thiophene-2-

yl)ethyl)amino)acetate

hydrochloride

2-(thiophen-2-yl)ethyl 4-

methylbenzenesulfonateH

ydroxide

MT 0.6722 Iso propyl Alcohol MT 0.1430

Isopropyl alcohol

hydrochloride

MT 0.2323 p-Toluenesulfonic acid MT 0.4100

water MT 2.0420 Water MT 2.0430


Stage-V

(S)-methyl 2-(2-

chlorophenyl)-2-((2-

(thiophene-2-

yl)ethyl)amino)acetate

hydrochloride

MT 0.8247 Clopidogrel Bisulphate MT 1.0000

Paraformaldehyde MT 0.072

Sulphuric Acid MT 0.2359 Hydrochloric Acid MT 0.087



2.6.9. Manufacturing process of Amlodipine

Step-I: 2-Hydroxyethylphthalimide (HEP) Procedure:

Charge toluene. Charge phthalic anhyride at 25-30oC. Stir for 15min. Heat the reaction mass to 90oC.

Add ethanolamine, at 90-100oC over a period of 1-2h. Raise the temperature to 100-106oC. Maintain

for 1hr. Raise the temperature to reflux point. Reflux for 12 h and remove water by azeotropic

distillation. Send sample to Q.C for TLC (absence of phthalic anhydride). If TLC is not OK, maintain till

TLC complies. Cool to 25-30oC over a period of8h.

Centrifuge the reaction mass at 25-30o C. Wash the cake with toluene, spin dry for 1hr. Unload the

material into double polythene bag weigh the product & label. Record the weight of product. Send

sample to Q.C for completeanalysis

Step – II :PHEEMA

Procedure:

Ensure the cleanliness of reactor (R-102). Charge toluene, Start flushing the reactor with nitrogen.

Draw toluene from the bottom valve of the reactor & send the sample to QC for moisture content

(moisture content < 0.05%). Meanwhile check the moisture content of the THF it should be < 0.1%.

Charge THF stir for 10 Minutes. Send an aliquot to QC for moisture content. It should be < 0.1%. Add

Sodium Hydride, in two lots (under N2 blanket). Cool the reaction mass from 25°C to 10°C. Add ethyl -



4 – chloroacetoacetate, in portions over a period of 9 – 11h at 10 – 15oC. Record addition time and

temperature for every 30min. slowly raise temperature from 15°C to 20°C. Add of HEP over a period of

10 to 12 h at 20°C-25°C. Maintain reaction mass for 12 – 16 h at 20°C-25°C. After 12 h maintenance

send sample to QC for TLC (absence of HEP). If TLC does not comply continue the reaction until TLC

complies. Add acetic acid slowly at 25°-30°C in 1 h and stir the mass for 1hr. Ensure that sodium

hydride is decomposed.

Meanwhile charge water in reactor (R-108) for quenching. Transfer the reaction mass from Reactor (R-

102) to R-108. Rinse the reactor R-102 with methanol. Stir the reaction mass in reactor (R-108) for 1hr

and settle for 1hr at 30°C – 35°C. Separate the bottom aqueous layer and discard. Give water washing

to the organic layer with water, stir for 30 min. and settle for 30 min. Separate the bottom aqueous layer

and discard. Repeat two washings with water separate the aqueous layer and discard. Collect the

organic layer. Transfer total organic layer from R-108 to R-103. Distill out toluene under 680 mm/Hg

vacuum and up to about 50°C. Cool the reaction mass to 30°-35°C at 680 mm/Hg. Add n-hexane, to

the reaction mass. Stir for 1 h and settle for 1 h. Separate the layers and collect bottom organic layer in

carboys.

Step – III : Procedure to Convert PHEEMA to phthaloylamlodipine.

Procedure:

Ensure the cleanliness of Reactor R-107. Charge IPA, PHEEMA and piperidine at 25°C-30°C followed

by acetic acid. At 25°C-30°C. Cool the mass to 15°C – 20°C and add slowly OCB at 15°C – 20°C over

a period of 3 – 4 h. raise the temperature from 20°C to 30°C. Maintain at 25°C -30°C for 36 to 40 h

under stirring. Send the sample to QC for TLC (absence of PHEEMA) if TLC does not comply maintain

till TLC complies. Transfer the reaction mass from R-107 to R-106 Apply vacuum to the Reactor R-106

Distill out IPA under vacuum 680 mm/Hg up to 50°C + 2°C. Ensure that reaction mass thick slurry.

(Record vacuum and temperature for every 1h). Cool the mass to 25°C -30°C. Transfer the organic

layer to R-107. If the mass is very thick charge acetic Acid. Stir for 30-40 minutes. Charge methyl

aminocrotonate at 25°C-30°C and stir for 30-40 min. Heat the mass 40°C – 45°C, maintain for 18 – 22

h at 40 – 45oC. (Record time and temperature for every 1h). Send the sample to QC for TLC (Absence

of OCB) If TLC does not comply maintain at 40°C-45°C till TLC complies. Slowly cool the mass to

20°C. Centrifuge the reaction mass in CF 101, spin dry and unload the crude cake into double poly

bags. Record weight of the product . Meanwhile charge water & acetic Acid in R-103. Charge the crude

cake. Stir for ½ h, Centrifuge the mass and wash the cake with water Spin dry for ½ h and unload the

wet cake. Send the sample to QC for HPLC analysis.

STEP – IV (Purification in toluene)

Procedure:

Ensure the cleanliness and dryness of reactor R-0 103. Charge toluene at room temperature. Charge

crude phthaloyl amlodipine under stirring at room temperature . Heat the reaction mass to 70°C-75°C.

Check for the dissolution if dissolution is OK separate the water layer and remove the particles from

bottom then Maintain for 1h at 70°C-75°C. Cool the mass to 0-5°C Maintain for 2h Centrifuge the

mass, spin dry for 30min and unload the wet cake into double polythene bags. Record the weight of

the product Collect toluene mother liquor in clean drums Send the sample to QC for HPLC analysis.



Step – V: Purification in Methanol

Procedure:

Ensure the cleanliness and dryness of Reactor R-105 Charge methanol at room temperature Charge

crude phthaloyl amlodipine under stirring at room temperature. Stir for 30min at room temperature.

Heat the reaction mass to 55°C – 60°C. Maintain 2h at 55 - 60°C. Slowly cool the reaction mass to

0°C. over a period 2-3h. Maintain 2 h at 0-5°C and centrifuge the mass. Wash the cake with chilled

methanol Spin dry for 1 h and unload the wet cake into double polythene bag. Send the sample to QC

for HPLC. Dry the material in tray drier at 45°C – 55°C for 8 h. Record time and temperature for every

½ h Send the sample to QC for moisture content and LOD If moisture content and Loss on Drying

(LOD) is OK then unload the material. If moisture content and LOD are not OK then dry the material

another 4 h. (moisture content: NMT 0.2%, LOD 0.5%) and check Melting Range.

Figure 2.11 : Process flow diagram of Amlodipine



Material balance of Amlodipine

STAGE 1

INPUT OUTPUT


Pthalic Anhydride MT 0.0687 N-Hydroxyethylphthalimide MT 0.088

Momoethanolamine MT 0.0286 Xylene MT 0.049

Xylene MT 0.049


TOTAL MT 5.1463 TOTAL MT 5.1463

STAGE 2

INPUT OUTPUT


N-

Hydroxyethylphthalim

ide

MT 0.088 Ethyl-4(2-phthalimido

ethoxy) acetoacetate

MT 0.1481

4-chloroethyl

acetoacetate


Sodium Hydride MT 0.011 Hydrogen MT 0.0009

Hydrochloric Acid MT 0.016 Water MT 5.0172

Water MT 5.000


STAGE 3

INPUT OUTPUT


Ethyl-4(2-phthalimido

ethoxy) acetoacetate

MT 0.1481 Amlodipine MT 0.25

Ortho-

chlorobenzaldehyde

MT 0.0652 Water MT 2.025

Methyl-3-amino

crtonate

MT 0.0534

Water MT 2.0083




2.6.10. Manufacturing Process of Ibuprofen

STAGE 1 (A) ISO BUTYL ACETO PHENONE STAGE

The product of this stage is the IBAP (Iso Butyl Aceto Phenone), which is formed by the chemical

reaction

Where Iso Butyl Benzene & Acetyl Chloride is the reactants and the reaction solvent is TCE (Tri Chloro

Ethylene). Hydrogen Chloride is generated as the reaction side product which comes in the vapor form and is

then Scrubbed with Water to form Hydrochloric Acid and reused in the DM plant.

STAGE 1 (b) ISO PROPYL CHLORO ACETATE STAGE.

This stage produces Iso Propyl Chloro Acetate from the reaction of the following

IPA (Iso Propyl Alcohol) & MCA (Monochloro Acetic Acid) are the reactants and IPCA (Iso Propyl Chloro

Acetate) is the reaction product whereas the water formed during the reaction is the side product. IPA is the

excess reactant and so MCA charged is always completely reacted.

2 .ALDEHYDE STAGE.

In this stage IBAP, IPCA, SPO & NaOH reacted together & form 2,4- Iso Butyl Phenyl Propanaldehyde, Iso

Propyl Alcohol, Sodium hydroxide, sodium chloride and carbon dioxide. The iso propyl alcohol is recovered by

distillation. The chemical reaction is as follows



3. IBUPROFEN STAGE

The aldehyde which has already been formed is now to be oxidized to get the required Product i.e. IBU–

PROFEN Salt chemically known as 2,4 – Iso Butyl Phenyl Propionic Acid. The chemical reaction for the

synthesis is as follows



Where the oxidizing Agent is Sodium Di Chromate. The chromic acid & water are the reaction

side products and Sulphuric Acid is the excess reactant. After the reaction is over, the formed

IBUPROFEN Salt is then extracted from the reaction mass by n – Hexane solvent extraction.

Rest of the reaction mass that contains Chromic Acid, Water & Sulphuric Acid is called as Green

Acid, which is used as a byproduct for manufacture of Basic Chrome Sulphate. Crystallization is

done to get the product in the solid stage and that is later on separated from the n – Hexane by

Centrifugation.

Cr2O3 + 3 H2O+ Na2SO4 = Green Acid

Green Acid is sale to Basic Chromium Sulphate manufacturers.

Figure 2.12 : Process Flow diagram of Ibuprofen



Material balance of Ibuprofen

Input Output

IBAP Stage


Unit Qty

Iso Butyl Benzene MT 29.56 Iso Butyl Acetophenone

MT 38.45

Acetyl Chloride MT 17.32 HCL MT 8.05

Water MT 42 Water MT 42.38


IPCA Stage


Unit Qty

Iso Propyl Alcohol MT 13.23 IPCA MT 29.82

Mono Chloro Acetic Acid

MT 20.85 Water MT 39.26

Water MT 35


Aldehyde Stage


Unit Qty

Iso Butyl Acetophenone

MT 38.45 Iso butyl phenyl propan aldehyde

MT 41.50

IPCA MT 29.82 IPA MT 26.22

Water MT 58.93 Carbon dioxide

MT 9.611

Sodium Propoxide MT 17.91 Sodium Chloride

MT 12.77

Water MT 55.009

Total MT 145.11 145.11

Ibuprofen Stage


Unit Qty

Iso butyl phenyl propan aldehyde

MT 41.50 Ibuprofen MT 45.00

Chromic Acid MT 33.20

Sodium Dichromate MT 65.75 Sodium Sulphate

MT 31.01

Sulphuric Acid MT 21.62 Water MT 52.67

Water MT 40.00 Oxygen MT 6.99




2.6.11. Manufacturing process of Lamotrigine

Stage-01:

Process water is charged in to the reactor & cooled to 5oC. Slowly sulfuric acid is added maintaining

temperature. Aminoguadine bicarbonate is added to above solution followed by 2,3-

dichlorocenzoylnitrile. Acetonitrile is added to reaction which acts as catalyst. Reaction mass is stirred

for 20 hrs at 45-50oC. After completion of reaction solid is filtered & washed with plenty of water, solid

is again suspended to aq. sodium hydroxide solution and filtered followed by washing with water, solid

is dried as LAM-0.1. Sodium sulphate (as a by-product) will be selling to authorize dealer.

Stage-02:

Ethanol is added to a reactor followed by Stage-01 material & reaction mass is refluxed for 8 hrs. After

completion of reaction, mass is distilled to half volume followed by cooling & solid is filtered & dried as

Lamotrigine

Figure 2.13 : Process Flow Diagram

Material balance Lamotrigine

Stage-1


Material

Unit Qty

2,3-

dichlorobenzonitrile

MT 0.0781 2-(2,3-

Dichloropheny

l)-2-

guanidinylimin

oacetonitrilehy

drogen

MT 0.1382



sulphate

Amino guanidine

bicarbonate

MT 0.0536 Carbon

dioxide

MT 0.01718

Sulphuric Acid MT 0.0386



Stage-2


Material

Unit Qty

2-(2,3-

Dichlorophenyl)-2-

guanidinyliminoacet

onitrilehydrogen

sulphate

MT 0.1382 2-(2,3-

Dichloropheny

l)-2-

guanidinylimin

oacetonitrile

hydrogen

sulphate

MT 0.100

Sodium Hydroxide MT 0.0315 Sodium

Sulphate

MT 0.055



2.6.12. Manufacturing Process of Phineramine base

Toluene is charged to a clean reaction vessel at 25-35oC followed by charging of 2-Benzyl pyridine

under nitrogen atmosphere. Cool the reaction mass to 5-10oC & Charge sodium amide under

Nitrogen atmosphere. Stir the reaction mass for some time at same temperature & slowly raise the

temperature of reaction mass to 30-35oC. Meanwhile in another reaction vessel charge purified water

at 25-35oC & caustic lye solution at 25-35oC. Charge toluene & Cool the mass to 0-5oC. Charge 2-

chloro-N,N-dimethyl ethylamine Hydrochloride & Stir the reaction mass for 30 minutes at same

temperature. Stop agitation & allow to settle the mass for 15 minutes. Separated the organic layer to

a dry vessel. Add anhydrous potassium carbonate to organic layer to remove the moisture. Decant off

organic layer & slowly add to above reaction mass at 30-35oC in approx. 1hr. Maintain the reaction

mass monitor the reaction progress by HPLC till reaction complies (2-Benzyl pyridine <10%).

After reaction completion cool the reaction mass to 20-25oC. Slowly add methanol & stir for 10- 15

minutes & then add slowly water to quench the reaction mass at 20-25oC. Stir the mass for 30

minutes. Adjust the pH of reaction mass to 4-4.5 using dil. HCl at 20-30oC & stir for 10 minutes.

Separate the layer & collected the toluene layer for recovery of unreacted 2-Benzyl pyridine.

Charge aq. Layer back to reaction vessel at 25-30oC. Charge toluene to reaction vessel at 25- 30oC,

Stir the mass for 10-15 minutes. Settle & separate the toluene layer for recovery of unreacted 2-

Benzyl pyridine. Charge aq. Layer back to reaction vessel at 25-30oC. Adjust the pH of reaction mass

to 10-11 using aq. NaOH solution & Charge Hexane, stir for 30 minutes. Settle & separate the organic



layer & collected in dedicated container. Again charge aq. Layer back to reactor. Charge Hexane to

reactor & stir for 30 minutes at 25-30oC. Settle & separate the organic layer & collected in dedicated

container. Charge the combine Hexane to reactor & heat to 40- 45oC. Charge activated carbon & stir

for 20-30 minutes at same temperature. Filter Hexane layer through hyflo & wash the hyflo bed with

Hexane, Distill off Hexane under vacuum below 60oC Unload the oil & check the wt. & quality of oil.

Distill of oil using short path distillation assembly to get pure oil.


Material balance of of Phineramine base

Stage-1


Material

Unit Qty

2-Benzyl pyridine MT 0.0704 Pheniramine

base

MT 0.1000

2-chloro N,N

dimethyl ethylamine

hydrochloride

MT 0.0605 Ammonia MT 0.0070

Sodium amide MT 0.0163 Hydrochloric

Acid

MT 0.0151

Sodium

chloride

MT 0.0243





2.6.13. Manufacturing Process of Ibuprofen Lysinate

Ibuprofen solution was obtained by dissolving ibuprofen in acetone, treated with activated carbon and

filtered. Similarly, DL-Lysine solution was prepared by dissolving DL-lysine in water, treated with

activated carbon and followed by filtration. Add drop wise lysine solution in Ibuprofen solution drop

wise. Obtained solid filtered to give Ibuprofen Lysinate.


Material balance of Ibuprofen Lysinate

Stage-1

Input Output


Ibuprofen MT 0.2922 Ibuprofen Lysinate MT 0.500

DL-Lysine MT 0.2092



2.6.14. Manufacturing Process of Ursodeoxycholic acid

Stage-01



Toluene is charged to reactor followed by charging of Cholic acid. Reaction mass is heated slowly

followed by Azeotropic reflux to remove water. After that cool the mass to 25-35, further cool to 5-10 &

maintain for 1 hr at same temperature. Filter the material & washed with chilled toluene. Charged the

wet cake back to reaction vessel followed by addition of methanol. Slowly added sulfuric acid & raise

the temperature of reaction mass to reflux. Stir the mass for 8-10 hrs & after completion of reaction

cool the mass to room temperature. Further cool the mass to zero degree & filter the material &

washed with chilled methanol, dry the wet cake in oven under vacuum till LOD came less than 1%.

Unload the dry material as UDCA-01.

Stage-02

Charge MDC into reaction at 25-30oC. Charged UDCA-01 & Dimethyl amino pyridine at same

temperature under stirring. Charge TEA & cool the mass to zero degree. Slowly added acetic

anhydride & stir at same temperature to for reaction completion. After reaction completion slowly add

water to reaction mass for reaction termination. Distill water azeotropically to remove MDC. Add ethyl

acetate & Heptane at 50-55 & stir. Cool the mass up to 20-22 & filter the solid. Wash the wet cake with

water followed by heptanes. Unload the wet cake & dry in air dryer at 500C till LOD came less than 1%.

Unload dry material as UDCA-02

Stage-03

Charge Ethyl acetate to reaction vessel. Charge UDCA-02 at 25-30oC & stir the mass. Charge

Sodium bromide & acetic acid at same temperature & cool the reaction mass to zero degree. Slowly

added sodium hypochlorite solution & stir the reaction mass at same temperature. Check the reaction

progress using HPLC. After reaction completion charge 10% aq. Sodium sulfite solution. Separate

the layer & wash the organic layer with aq.

Sodium bicarbonate solution. Charge DM water to organic layer & distill of ethyl acetate

azeotropically, cool the mass & filter the solid. Wash the wet cake with water & dry the solid in oven

under vacuum till LOD came NMT 0.5%. Unload the dry solid as UDCA- 03

Stage-04

Charge triethylene glycol to a reaction vessel. Charge UDCA-03 at 25-30oC & stir the mass. Slowly

added aq. Hydrazine hydrate solution. Charge 1-octanol in catalytic quantity & raise the temperature

of reaction to get clear solution. Slowly added aq. KOH solution under heating & start azetropic

distillation to remove water. After reaction completion cool the mass & add dil HCl to reaction vessel

to quench the reaction mass. Extract the reaction mass using ethyl acetate. Separate the organic

layer & again extract aq. Layer using ethyl acetate. To combined organic layer wash with aq. Sodium

bicarbonate. Wash the organic layer with aq. Sodium chloride & then distil of ethyl acetate completely

under vacuum below 45 to give UDCA-04.



Stage-05

Charge n-propanol & UDCA-04 to reaction vessel & stir to get a clear solution. Charge sodium

bromide & acetic acid followed by addition of DM water. Cool the reaction mass & slowly add

sodium hypochlorite solution. Maintain the reaction & after reaction completion slowly charge

aq. Sodium sulfite. Distill off water & n-propanol azeotropically. Cool the reaction mass & add

water. Slowly adjust the pH using Dil HCl & filter the solid. Wash the wet cake with Water & re

crystallize the solid in methanol, dry the solid in oven under vacuum till LOD came below

0.5%. Unload the solid as UDCA-05

UDCA-06

Charge IPA & tert-butoxide to a reaction vessel & stir to get a clear solution. Charge UDCA-05

& stir. Charge the reaction mass to pressure vessel. Slowly apply Hydrogen gas up to 3 bar &

raise the temperature of reaction mass up to 90 degree. Monitor the reaction Progress by

HPLC & after completion of reaction, release the pressure & filter the mass. Distill off IPA &

add water to residue. Slowly added sulfuric acid to adjust the pH 7-8 & again distill water &

traces of IPA. Charge water & heat the mass, adjust the pH to 2-2.5. Cool the mass & filter the

solid. Dry the wet cake in oven under vacuum till LOD came less than 0.5%. Unload the solid

as UDCA-06

UDCA-07

Charge Methyl ethyl ketone & UDCA-06 to reaction vessel. Heat the mass to 75-80 degree

& slowly add TEA. Stir the reaction mass & slowly cool to 20-25 degree. Filter the mass & re

crystallize the solid using methyl ethyl ketone. Dry the solid in oven till LOD came less than

0.5%. Unload the dry solid as UDCA-07

UDCA

Charge purified water & UDCA-07 to reaction vessel at 25-30oC. Heat the reaction mass

slowly added aq. NaOH solution to get a clear solution. Further heat the reaction mass to 80-

85oC & adjust the pH of reaction mass to 2.4 using dil. Sulfuric acid. Cool the reaction mass

to 35-40oC & filter the mass. Wash the wet cake with purified water & dry the solid in oven

under vacuum below 85 degree till LOD came below 0.5%. Unload the dry solid as UDCA &

submit the sample in QC for complete analysis.



Figure 2.16 Process flow diagram Ursodeoxycholic acid



Material balance of Ursodeoxycholic acid

Stage-1

Input Output


Cholic Acid MT 0.2601 Methyl Cholate MT 0.2691

Sulphuric Acid MT 0.0624 Sulphuric Acid MT 0.0624

Methanol MT 0.0204 Water MT 2.0114

Water MT 2.000


Stage-2

Input Output


Methyl Cholate MT 0.2691 Methyl -3a,7a-diacetoxy-12a-hydroxy chlolonate

MT 0.3220

Acetic Anhydride MT 0.1312 Acetic Acid MT 0.076



Stage-3

Input Output


Methyl -3a,7a-diacetoxy-12a-hydroxy chlolonate

MT 0.322 Methyl 3a,7a-diacetoxy-12a-ketocholanate

MT 0.3213

Acetic Acid MT 0.038 Sodium Acetate MT 0.052

Hypochlorite MT 0.047 Hydrochloric Acid MT 0.0234



Stage-4

Input Output


Methyl 3a,7a-diacetoxy-12a-ketocholanate

MT 0.321 Chenodeoxy cholic acid

MT 0.2500

Hydrazine Hydrate MT 0.020 Nitrogen MT 0.017

Potassium Hydroxide

MT 0.072 Methanol MT 0.020

Hydrochloric Acid MT 0.046 Acetic Acid MT 0.076

Potassium Chloride MT 0.094



Stage-5

Input Output




Chenodeoxy cholic acid

MT 0.250 3a-hydroxy-7-keto cholanic acid

MT 0.248

Acetic Acid MT 0.038 Sodium Acetate MT 0.052

Hypochlorite MT 0.047 Hydrochloric Acid MT 0.023



Stage-6

Input Output


3a-hydroxy-7-keto cholanic acid

MT 0.248 Ursodeoxy cholic acid MT 0.2500

Hydrogen Gas MT 0.0001 Tert Butanol MT 0.0942

Pot tert Butoxide MT 0.1442 Potassium Sulphate MT 0.1009

Sulphuric Acid MT 0.0631



Stage-7

Input output


Ursodeoxy cholic acid

MT 0.2500 Ursodeoxy cholic acid TEA salt

MT 0.3143

Triethylamine MT 0.0649



Stage-8

Input Output


Ursodeoxy cholic acid TEA salt

MT 0.3143 Ursodeoxy cholic acid MT 0.2500

Sulphuric Acid MT 0.0649 Triethylamine MT 0.0643

Sodium Hydroxide MT 0.051 Sodium Sulphate MT 0.090



2.6.15. Manufacturing Process of Quetiapine

STAGE – I Formation of 11- Chlorodibenzo[b,f][1,4]thiazepine

Stage-I.



Charged toluene as asolvent in reaction vessel. ChargedDibenzo[b,f][1,4]thiazepin-11(10H)-

one,Potassium carbonate and N-methyl morpholine into it. Stirr the reaction mixture at room

temperature followed by addition of phosphorous oxy chloride (POCl3). Reflux the reaction

mass. After reaction completion quench the reaction mass with aq. NaOH solution. Separate

organic layer and aqueous layer. Wash organic layer with water. Washed toluene layer used

in next stage.

STAGE – I Formation of Quetiapine

Stage-II.

Charged piperazinylethoxyethanol into reaction vessel. Reflux the reaction mixture under

stirring. After reaction completion quench the reaction mass with aqueous sodium hydroxide

solution. Separate organic layer and aqueous layer. Transfer aqueous layer to ETP.

Transfer organic layer into reaction vessel. Charged DM water and Citric acid monohydrate

into it followed by dropwise addition of hydrochloric acid. Stir the reaction mixture at room

temperature. Filtered the reaction mass and purified the quetiapine using chloroform.




Material balance of Quetiapine

STAGE 1

INPUT OUTPUT


dibenzo[b,f][1,4]thiaz

epin-11(10H)-one

MT 0.7721 11-

chlorodibenzo[b,f][1,4]thia

zepine

MT 0.8348

Phosphorus Oxy

chloride

MT 0.5208 Trisodium Phosphate MT 0.5568

Sodium Hydroxide MT 0.4076 Hydrochloric Acid MT 0.2480



STAGE 2

INPUT OUTPUT


11-

chlorodibenzo[b,f][1,4

]thiazepine

MT 0.8348 2-(2-(4-

(dibenzo[b,f][1,4]thiaze

pin-11-yl)piperazin-1-

yl)ethoxy)ethanol

MT 1.3028

2-(2-(piperazin-1-

yl)ethoxy)ethanol



Water MT 3.0000


STAGE 3

INPUT OUTPUT


2-(2-(4-

(dibenzo[b,f][1,4]thiaz

epin-11-yl)piperazin-

1-yl)ethoxy)ethanol

MT 2.6056 Quetiapine

Hydrochloride

MT 3.0000

Fumaric Acid MT 0.3983 Water MT 3.0039

Water MT 3.0000


2.6.16. Manufacturing Process of Dex-ibuprofen

Stage 01:

Toluene is charged to a reaction vessel followed by Ibuprofen. Temperature of reaction mass is

increased and N-octyl D Glucamine is charged. Reaction mass is further heated to get a clear

solution. Reaction mass is cooled to room temperature & solid is filtered & dried to give N-octyl

D Glucamine salt of Ibuprofen. Mother liquor is stored to recover undesired isomer.

Stage 02:



Water is charged to a reaction vessel at room temperature followed by stage- 01 material. Aq.

Solution of KOH is added slowly & reaction mass is stirred for 2 hrs at same temperature. Solid

is filtered to give N-octyl-D Glucamine, which is dried, tested & reused in next batch. Mother

liquor is charged to another reaction vessel & pH is adjusted with acetic acid. Solid is filtered to

give Dex Ibuprofen. Material is dried & submitted for complete analysis.


Material balance of Dex-ibuprofen

STAGE 1

INPUT OUTPUT


Ibuprofen MT 0.5 IBD Complex MT 1.2136

N-octyl –D-glucamine MT 0.7207 Water MT 2.0071

Water MT 2.0000


STAGE 2

INPUT OUTPUT


IBD Complex MT 1.2136 Dex-Ibuprofen MT 0.5000

Potassium Hydroxide MT 0.1371 N-octyl-D-glucamine MT 0.7174

Water MT 2.0430 Potassium

Hydroxide

MT 0.1357

Water MT 2.0406


2.6.17. Manufacturing Process of Gabapentene

Stage-I

cyclohexane & cyclohexanone is charged to a reaction vessel followed by methyl

cyanoacetate & ammonium acetate, reaction mass is heated to reflux temperature and



remove water azeotropically. Cool & Filter the reaction mass. Filtrate ML is diluted water

followed by layer separation. Organic phase transfer for recovery to give stage-01.

Stage-II

Methanol & water is charge at atmospheric temperature followed by sodium cyanide.

Then stage-1 is added in 20-30 min. Heat the reaction mass to reflux temperature and

maintain. Allow RM to cool to & Add water slowly over period. Distill out methanol.

Filtered off the reaction mass, unload the wet cake. Dry the wet material.

Stage-III&IV

Charge ethanol & stage-2 material to reaction vessel. Cool the reaction mass & Purge the

dry HCl gas to reaction mass. Stir the reaction mass till completion, apply vacuum and

distilled out ethanol. Allow Reaction mass to cool to 25-30°C. Add slowly water & toluene.

Adjust the pH of reaction mixture by using 1N NaOH solution. Settle and separate out

layers. Distilled out toluene under vacuum & then cool to Room temperature. Unload the

stage-3.

Arrange clean and dry autoclave. Charge Stage-4 at room temperature. Charge Raney

Nickel at room temperature. Charge potable water & apply the nitrogen pressure to

autoclave and start agitation then release the nitrogen pressure. Apply the hydrogen

pressure and start heating. Heat the reaction mass to till reaction completion. Filter the

reaction mass through hyflo bed & Distilled out water under vacuum to get thick oily mass

to semi solid. Charge conc. HCl at room temperature. Heat the reaction mass to &

Distilled out hydrochloric acid under vacuum, precipitated gabapentin hydrochloride

filtered through Buckner funnel & Dry the material.

Stage-VII:

Charge Stage-6 at room temperature. Charge DM water & Charge Methylethylketone at

room temperature. Heat the reaction mass & Adjust the pH by using Liq. NH3 solution.

Gradually cool the reaction mass & Maintain. Filtered the solid through Buckner funnel &

Charge Methanol & wet cake at room temperature. Heat the reaction mass to reflux

temperature. Maintain the reaction mass at reflux temperature. Cool the reaction mass,

Filter the precipitated solid and dry the material.By-Product Ammonium chloride sell to

authorized dealer.



Figure 2.19 Process flow diagram

Material balance of Gabapentene

STAGE 1

INPUT OUTPUT


Cyclohexanone MT 2.8655 Methyl-2-cyano-

2cyclohexylideneace

tate

MT 5.2330



Methyl Cyanoacetate MT 2.8933 Ammonium Acetate MT 2.2733

Ammonium Acetate MT 2.2733 Cyclohexane MT 2.4573

Cyclohexane MT 2.4573 Water MT 2.5258

Water MT 2.0000


STAGE 2

INPUT OUTPUT


Methyl-2-cyano-

2cyclohexylideneacet

ate

MT 5.2330 1-

(cyanomethyl)cycloh

exanecarbonitrile

MT 4.3272

Sodium Cyanide MT 1.4417 Methanol MT 0.9449

Sodium Hydroxide MT 1.1679


Carbon Dioxide MT 1.2847


STAGE 3 and 4

INPUT OUTPUT


1-

(cyanomethyl)cycloh

exanecarbonitrile

MT 4.3272 1-

(cyanomethyl)cycloh

exanecarbonitrile

MT 5.7300

Hydrochloric Acid MT 2.1315 Sodium Chloride MT 1.7052

Ethanol MT 1.3587 Ammonium Chloride MT 1.5618


Sodium Hydroxide MT 1.1679 Toluene MT 2.6903

Toluene MT 2.6903


STAGE 5 and 6

INPUT OUTPUT


1-

(cyanomethyl)cycloh

exanecarbonitrile

MT 5.7300 2-(1-

(aminomethyl)cycloh

exyl)aceticacid

MT 6.0470

Raney-Ni MT 1.7136 Raney-Ni MT 1.7136

Methylethylketone MT 2.1267 Methylethylketone MT 2.1267


Hydrochloric Acid MT 1.0657 Hydrochloric Acid MT 1.0657


STAGE 7

INPUT OUTPUT


2-(1-

(aminomethyl)cycloh

exyl)aceticacid

MT 6.0470 Gabapentene MT 5.000



Liquid Ammonia MT 0.5013 Ammonium Chloride MT 1.5618

Methylethylketone MT 2.1055 Methylethylketone MT 2.1055


Methanol MT 0.9355 Methanol MT 0.9355


2.6.18. Manufacturing Process of Pentaprozole

Stage-01:

Maltol is reacted with DMS in presence of potassium carbonate using acetone as solvent under

reflux, reaction mass is distilled under vacuum, aq. Ammonia is charged and reaction mass is

further heated, after distillation 3-Methoxy-2-methyl-pyridine-4-one is crystallized & filtered with

acetone.

Stage-02:

Stage 01 is reacted with phosphorusoxychloride, reaction mass is distilled and further reacted

under heating with hydrogen peroxide in presence of acetic acid, oil obtained from distillation of

reaction mass is allowed to react with sodium hydroxide in presence of methanol under reflux,

after reaction completion reaction mass is distilled and reacted with acetic anhydride under

heating, distillation gave crude oil, alkaline pH of reaction mass is maintained by caustic lye and

product is extracted in MDC, which is further reacted with thionyl chloride to give 3,4- dimethoxy-

2-chloromethylpyridine. Hydrochloride.Trisodium phosphate is generated as by product which

shall be converted in calcium phosphate by reaction with CaCl2, The final byproduct i.e. Calcium

Phosphate shall be sell to authorized dealer.

Stage-03:

3,4-dimethoxy- 2- chloromethyl pyridine Hydrochloride is dissolved in water & aq. Layer is

reacted with 5-difluoromethoxy-2- mercaptobenzimidazole in presence Sodium hydroxide. After

reaction completion material is extracted with MDC as solvent to give 5- difluromethoxy-2-

[[(3,4-dimethoxypyridin-2-yl]methyl]thio]- benzimidazole. MDC layer undergoes oxidation

reaction with hypo solution under cooling, after completion of reaction, MDC is distilled off & aq.

sodium hydroxide solution in acetone is added & precipitated material is filtered under cooling to

give Sodium-5-difluromethoxy-2- [[(3,4-dimethoxypyridin-2-yl]methyl]sulfinyl]- benzimidazole.

Sesquihydrate (Pantoprazole Sodium sesquihydrate).






Material balance of of Pentaprozole

STAGE 1

INPUT OUTPUT


3-Hydroxy-2methyl-4H-

pyran-4-one

MT 0.2916 3-methoxy-2-methyl-4-

H-pyran-4-one

MT 0.3240

Di Methyl Sulphate MT 0.2946 Potassium bicarbonate MT 0.2314

Potassium Carbonate MT 0.3231 Potassium methyl

Sulphate

MT 0.3472



STAGE 2

INPUT OUTPUT


3-methoxy-2-methyl-4-

H-pyran-4-one

MT 0.3240 3-Methoxy-2-methyl-

pyridine-4-(1-H)-one

MT 0.3217

Ammonia solution MT 0.0810 Water MT 1.0833

Water MT 1.0000


STAGE 3

INPUT OUTPUT


3-Methoxy-2-methyl-

pyridine-4-(1-H)-one

MT 0.3217 4-Chloro-3-methoxy-2-

methyl-pyridine

MT 0.3645

Phosphoryl Chloride MT 0.3585 Trisodium phosphate MT 0.3794

Sodium Hydroxide MT 0.2777 Hydrochloric Acid MT 0.1689



STAGE 4



INPUT OUTPUT


4-Chloro-3-methoxy-2-

methyl-pyridine

MT 0.3645 4-Chloro-3-methoxy-2-

methylpyridine-1-oxide

MT 0.4016

Acetic Acid MT 0.1388 Acetic Acid MT 0.1388

Hydrogen Peroxide MT 0.0795 Water MT 1.0424

Water MT 1.0000


STAGE 5

INPUT OUTPUT


4-Chloro-3-methoxy-2-


MT 0.4016 3,4-dimethoxy-2-


MT 0.3912

Sodium Methoxide MT 0.1266 Sodium Chloride MT 0.1250



STAGE 6

INPUT OUTPUT


3,4-dimethoxy-2-


MT 0.3912 (3,4-

dimethoxypyridine-2-

yl) methyl acetate

MT 0.4884

Acetic anhydride MT 0.2384 Acetic Acid MT 0.1388



STAGE 7

INPUT OUTPUT


(3,4-dimethoxypyridine-

2-yl) methyl acetate

MT 0.4884 (3,4-

dimethoxypyridine-2-

yl) Methanol

MT 0.3912

Sodium hydroxide MT 0.0935 Sodium acetate MT 0.1898



STAGE 8

INPUT OUTPUT


(3,4-dimethoxypyridine-

2-yl) Methanol

MT 0.3912 2-(Chloromethyl)-3,4-

dimethoxypyridine

hydrochloride

MT 0.5185

Thionyl chloride MT 0.2782 Sulphur dioxide MT 0.0148





STAGE 9

INPUT OUTPUT


2-(Chloromethyl)-3,4-

dimethoxypyridine

hydrochloride

MT 0.5185 5-(Difluoromethoxy)-2-

{[(3,4-dimethoxy

pyridine-2-yl

)methyl]sulfonyl}-1H-

benzimidazole

MT 0.8495

5-(difluromethoxy)-1H-

benzimidazole-2-thiol



Water MT 1.0000


STAGE 10

INPUT OUTPUT


5-(Difluoromethoxy)-2-

{[(3,4-dimethoxy

pyridine-2-yl

)methyl]sulfonyl}-1H-

benzimidazole

MT 0.8495 Pantaprazole Sodium MT 1.0000

Sodium Hypochlorite MT 0.1741 Sodium Chloride MT 0.1354


Water MT 1.0625


2.6.19. Manufacturing process of Losartan Potassium

Stage-01:

Chloroform is charged to a reaction vessel at room temperature. O- tolylbenzonitrile is charged

and reaction mass is stirred. Bromination is done under heating using Dibromo Hydrantoin &

benzoyl peroxide. Reaction mass is quenched using water & organic layer is distilled. Toluene is

charged to reaction vessel, followed by water and CS flakes. 2-Butyl-4-chloro-5-formylimidazole

is added and reaction mass is stirred at room temperature, followed by addition of TBAB,

reaction mass is stirred till reaction completion, layer is separated and organic layer is charged to

reaction vessel, methanolic solution of sodium boro-hydride is added to reaction mass under

stirring, after reaction completion solid is filtered and dried as stage-01 material. By product

Sodium borotrihydrate will be sell to authorized dealer (Ansh Chem Tech).

Stage-02:

Toluene & stage-01 material is charged to reaction vessel followed by TEA hydrochloride,

reaction mass is stirred and sodium azide is added, reaction mass is refluxed and reaction

completion temperature is brought to room temperature, pH of reaction mass is adjusted to 7

using acetic acid, solid thus formed is filtered and dried as stage-02 compound.



Stage-03:

IPA is charged to reaction vessel followed by KOH, reaction mass is stirred to get a clear

solution. Stage02 material is charged and stirred to get dissolved. Reaction mass is distilled and

1.5 Volume IPA is charged, reaction mass is cooled and stirred for 2 hrs. Solid is filtered and

dried to give Losartan potassium






Material balance of losartan Potassium

STAGE 1

INPUT OUTPUT


4'-methylbiphenyl-2-

carbonitrile

MT 0.4186 4'-

(bromomethyl)biphe

nyl-2 -carbonitrile

MT 0.5900

1,3-dibromo-5,5-

dimethylhydantoin

MT 0.6264 Hydantion MT 0.4488



STAGE 2

INPUT OUTPUT


4'-

(bromomethyl)biphen

yl-2 -carbonitrile

MT 0.5900 4'-{[2-butyl-4-chloro-

5-(carbaldehyde)-

1H-imidazol-1-

yl]methyl}biphenyl-2-

carbonitrile

MT 0.8199

2-butyl-4-chloro-1H-

imidazole-5-

carbaldehyde

MT 0.4088 Sodium Bromide MT 0.2222


Water MT 5.0000


STAGE 3

INPUT OUTPUT


4'-{[2-butyl-4-chloro-

5-(carbaldehyde)-1H-

imidazol-1-


carbonitrile

MT 0.8199 4'-{[2-butyl-4-chloro-

5-(hydroxymethyl)-

1H-imidazol-1-


carbonitrile

MT 0.8242

Sodium Borohydride MT 0.0828 Sodium Borate MT 0.1817


Hydrogen MT 0.0130


STAGE 4

INPUT OUTPUT




4'-{[2-butyl-4-chloro-

5-(hydroxymethyl)-

1H-imidazol-1-


carbonitrile

MT 0.8242 Losartan MT 0.9175

Sodium azide MT 0.1426 Sodium Acetate MT 0.1778


Acetic Acid MT 0.1310


STAGE 5

INPUT OUTPUT


Losartan MT 0.9175 Losartan Potassium MT 1.0000

Potassium Hydroxide MT 0.1426 Water MT 5.0601

Water MT 5.0000


2.6.20. Manufacturing Process of Fexofenadine

STAGE – I Formation of methyl-2-(4-(4-(4-(hydroxydiphenylmethyl)piperidin-1-

yl)butanoyl)phenyl)-2- methylpropanoate

Stage-I.

Charged DMF as asolvent in reaction vessel. Charged Diphenyl(piperidin-4-yl)methanol , Methyl-

2-(4-(4- chlorobutanoyl)phenyl)-2-methylpropanoate , K2CO3 and KI into it. Reflux for 16 hr

under stirring.

as a solvent in above reaction. After reaction completion ,quenched the reaction mass in water.

Separate organic layer and aqueous layer and extract aqueous layer with ethyl acetate and

washed organic layer with water.washing organics mass is distilled and recovered ethyl acetate

and DMF.methyl-2-(4-(4-(4- (hydroxydiphenylmethyl)piperidin-1-yl)butanoyl)phenyl)-2-

methylpropanoate used in next stage.

Stage-II.

Stage – I hydrolysed with aq. NaOH in presence of methanol. Reflux reaction mass under

stirring. After reaction completion filtered the reaction mass and proceed the solid obtained for

reduction with sodium borohydride in presence of toluene and methanol and maintain reaction

mass for 15 hr at room temperature. After reaction completion adjust ph of reaction mass with dil.

Acetic acid. Filtered the reaction mass and purified fexofenadine with iso propyl alcohol. Filtered

it and dried fexofinadine in oven.




Material balance of Fexofenadine

STAGE 1

INPUT OUTPUT


Diphenyl(piperidin-4-

yl)methanone

MT 0.2668 methyl-2-(4-(4-(4-

(hydroxydiphenylmet

hyl)piperidin-1-

yl)butanoyl)phenyl)-

2-methylpropanoate

MT 0.5119

Methyl-2-(4-(4-

chlorobutanoyl)pheny

l)-2-

methylpropanoate

MT 0.2819 Carbonic Acid MT 0.0309

Potassium Carbonate MT 0.0688 Potassium Chloride MT 0.0743



STAGE 2

INPUT OUTPUT


methyl-2-(4-(4-(4-

(hydroxydiphenylmet

hyl)piperidin-1-

yl)butanoyl)phenyl)-

2-methylpropanoate

MT 0.5119 Fexofenadine MT 0.5000



Sodium Hydroxide MT 0.0400 Methanol MT 0.0319

Sodium Borohydride MT 0.0377 Sodium

borotrihydride

MT 0.0830

Acetic Acid MT 0.0598 Hydrogen MT 0.0060

Water MT 2.0539 Sodium Acetate MT 0.0810

Water MT 2.0014


2.6.21. Manufacturing process of Ibuprofen sodium

Methanol is charged to a reaction vessel at room temperature followed by charging of Ibuprofen.

Reaction mass is stirred to till clarity. Reaction mass is heated & aq. Sodium Hydroxide solution

is added. Reaction mass is maintained under heating till reaction completion. After that methanol

is distilled out followed by addition of cyclohexane.

Cyclohexane is again distilled azeotropically. Reaction mass is cooled to RT & solid is filtered

& dried to give Ibuprofen sodium.


Material balance of Ibuprofen sodium

STAGE 1

INPUT OUTPUT


Ibuprofen MT 1.5610 IBU Sodium MT 2.0000


Water MT 5.1362


2.6.22. Manufacturing Process of CMIC Chloride

CMIC acid

Methanol and OCB are heated. HAS dissolved in water is added to the reaction mixture.

The oxime formed is brought in contact with chlorine. After chlorination is completed,

nitrogen gas is passed &methanol distillation is carried out The chloro-oxime is subjected to

neutralization by adding soda ash and recovered sodium sulphate sale to paper and glass

industries.. The pH of the reaction is adjusted between 1.0-1.2. In another flask sodium

hydroxide flakes and methanol are mixed together charged to methylacetoacetate to form

sodium salt of MAA. The sodium salt of MAA is added to chloro-oxime mass; the reaction

mass is heated & after reaction completion, cooled product is then subjected to

acidification with 20% sulphuric acid solution. The pH is maintained,after acidification the

reaction mass is filtered.



CMIC Chloride

Toluene and DMF are charged to CMIC Acid and reaction mixture is heated. Meanwhile

prepare solution of triphosgene in toluene. Slowly add the solution to reaction mixture.

Then maintain the reaction mixture, after maintaining cool the reaction mass to room temp.

Settle and separate the organic layer. Distill out toluene under vacuum. Charge n-Hexane

to oily residue.Heat to get clear reaction mass, further cool & maintain. Filter the solid under

nitrogen to give CMIC chloride.Sodium sulphate as a by-product will sell to authorized

dealer.


2.6.23. Material balance of CMIC Chloride

STAGE 1

INPUT OUTPUT


2-ChloroBenzaldehyde MT 1.0978 Oxime MT 1.215



Hydroxylamine

Sulphate

MT 0.6468 Sulphuric Acid MT 0.383



STAGE 2

INPUT OUTPUT


Oxime MT 1.215 Chloroxime MT 1.4841

Sulphuric Acid MT 0.383 Sodium Chloride MT 0.4564

Chlorine MT 0.5593 Carbondioxide MT 0.3436

Sodium Carbonate MT 0.8277 Sodium Sulphate MT 0.5546



STAGE 3

INPUT OUTPUT


Chloroxime MT 1.4841 CMIC Ester MT 1.9655

Methyl Acetoacetate MT 0.9160 Sodium Chloride MT 0.4564

Sodium Hydroxide MT 0.3155



STAGE 4

INPUT OUTPUT


CMIC Ester MT 1.9655 CMIC Acid MT 1.8509


Sulphuric Acid MT 0.3867 Methanol MT 0.2502



STAGE 5

INPUT OUTPUT


CMIC Acid MT 1.8509 CMIC Chloride MT 2.0000

Triphosgene MT 0.7803 Hydrochloric Acid MT 0.2847

Carbon Dioxide MT 0.3437



2.6.24. Manufacturing Process of DCMIC Chloride

DCMIC Acid

Methanol and DCB are heated. HAS dissolved in water is added to the reaction mixture.

The oxime formed is brought in contact with chlorine, methanol distillation is carried out.

The chloro-oxime is subjected to neutralization by adding soda ash and recovered sodium

sulphate sale to paper and glass industries. In another flask sodium hydroxide flakes and

methanol are mixed together and charged to methyl aceto acetate to form sodium salt of



MAA. The sodium salt of MAA is added to chloro- oxime mass; the reaction mass

temperature is maintained under cooling. The cooled product is then subjected to

acidification with 20% sulphuric acid solution. The pH is maintained,the reaction mass is

filtered to give DCMIC acid

DCMIC Chloride

Toluene and DMF are charged to DCMIC Acid and reaction mixture is heated. Meanwhile

prepare solution of triphosgene in toluene. Slowly add the solution to reaction mixture. After

maintaining cool the reaction mass to room temp. Settle and separate the oily layer. Distill

out toluene under vacuum. Charge n-Hexane .Heat to get clear reaction mass. Cool to RT.

and filter the solid under nitrogen. Sodium sulphate as a by-product will sell to authorized

dealer.






Material balance of DCMIC Chloride

STAGE 1

INPUT OUTPUT


DiChloroBenzaldehyde MT 0.3011 Oxime MT 0.3270

Hydroxylamine

Sulphate




STAGE 2

INPUT OUTPUT








STAGE 3

INPUT OUTPUT


Chloroxime MT 0.3863 DCMIC Ester MT 0.4923



Water MT 1.000


STAGE 4

INPUT OUTPUT


DCMIC Ester MT 0.4923 DCMIC Acid MT 0.4682





STAGE 5

INPUT OUTPUT


DCMIC Acid MT 0.4682 DICMIC Chloride MT 0.5000


Water MT 1.000 Carbon Dioxide MT 0.075

Water MT 1.0031




2.6.25. Manufacturing Process of FCMIC Chloride

FCMIC Acid

Methanol and 2-chloro-6-fluorobenzaldehyde are heated, HAS dissolved in water is added

to the reaction mixture and reaction is maintained. The oxime formed is brought in contact

with chlorine. After chlorination is completed, methanol distillation is carried out. The

Fluorochloro-oxime is subjected to neutralization by adding soda ash recovered sodium

sulphate sale to paper and glass industries. In another flask sodium hydroxide flakes and

methanol are mixed together to prepare sodium methoxide solution &Charged to

methylacetoacetate to form sodium salt of MAA. The sodium salt of MAA is added to chloro-

oxime mass. The above reaction is subjected to methanol distillation under atmospheric

condition.The cooled product is then subjected to acidification with 20% sulphuric acid

solution. After acidification the reaction mass is filtered.

FCMIC Chloride

Toluene and DMF are charged to FCMIC Acid and reaction mixture is heated. Meanwhile

prepare solution of triphosgene in toluene. Slowly add the solution to reaction mixture.

Then maintain the reaction mixture. After maintaining cool the reaction mass to room

temp. Settle and separate the oily layer. Distill out toluene under vacuum. Charge n-Hexane

.Heat to get clear reaction mass. cool and filter the solid under nitrogen. Sodium sulphate as

a by-product will be sell to authorized dealer.




Material balance of FCMIC Chloride



STAGE 1

INPUT OUTPUT


FlouroBenzaldehyde MT 0.2892 Oxime MT 0.3166

Hydroxylamine

Sulphate




STAGE 2

INPUT OUTPUT








STAGE 3

INPUT OUTPUT


Chloroxime MT 0.3794 FCMIC Ester MT 0.4919



Water MT 1.0000


STAGE 4

INPUT OUTPUT


FCMIC Ester MT 0.4919 FCMIC Acid MT 0.4663





STAGE 5

INPUT OUTPUT


FCMIC Acid MT 0.4663 FCMIC Chloride MT 0.5000


Water MT 1.000 Carbon Dioxide MT 0.080

Water MT 1.0025




2.6.26. Manufacturing Process of MIBT

Stage-I.

m – Xylene is charged in reaction vessel. Charged sodium metal and potassium carbonate

into it, oleic acid used as a emulsifying agent in above reaction,Raise the temperature of

reaction mass and apply pressure of propylene. Maintain the reaction mass at elevated

temperature under pressure. After reaction completion the reaction mass quenched with

methanol and water. Separate organic layer and aqueous layer. Distilled out MIBT using

fractional column.


Material balance of MIBT

STAGE 1

INPUT OUTPUT


M-Xylene MT 7.160 MIBT MT 10.000

Propylene MT 2.867 Water MT 10.027

Water MT 10.00


2.6.27. Manufacturing Process of Propyl acetate

Raw material (Propanol and acetic acid) is fed to Reactor with PTSA as a catalyst. Reaction

takes place in reactor to give propyl acetate. Material from reactor is charged to crude

distillation column where distillation takes place. Acetic acid from the bottom of column sent

back to reactor. Material from the top of crude distillation column fed to extractor. In extractor,

material is washed with DM water to remove unreacted alcohol in material. After that material

is charged to final distillation to remove water. Propyl acetate is withdrawn from the bottom of

the column. The water used in washing of propyl acetate is sent to recovery column, where

the recovered propyl acetate and propanol is sent back to the reactor.


Material balance of Propyl acetate



STAGE 1

INPUT OUTPUT


Propyl Alcohol MT 11.76 Propyl Acetate MT 20.00

Acetic Acid MT 11.88 Water MT 13.64

Water MT 10.00


2.6.28. Manufacturing Process of HEEP

Stage-01: Water is charged to a reactor at room temperature. Piperazine is charged & reaction

mass is stir to get a clear solution. Reaction mass is heated & followed by addition of 2-

chloroethoxy ethane. Reaction is maintained under heating & after completion of reaction mass

is cooled & centrifuged to give salt of piperazine which is reused in next reaction. Mother liquor is

distilled off to give pure 1- 2-(2-hydroxyethoxy) ethyl piperazine (HEEP).


Material balance of HEEP

STAGE 1

INPUT OUTPUT


Piperazine MT 0.4936 HEEP MT 1.0000

2-(2-chloroethroxy)

ethanol

MT 0.7219 Hydrochloric Acid MT 0.2095



2.6.29. Manufacturing Process of Methyl – 2- amino – 3 – chloropropionate HCL

Stage-I.

Charged methanol as asolvent in reaction vessel. Chargedserine followed by addition of thionyl

chloride. Reflux the reaction mixture for 6 hours. After reaction completion distill out methanol

completely from the reaction mass and then charged ethyl acetate in reaction. Stir the reaction

mass. Filtered it and dried to give D-Serine methyl ester hydro chloride.

Stage-II.

Charged chloroform in reaction vessel. Charged D-Serine methyl ester hydro chloride into it

followed by addition of thionyl chloride. Heat the reaction mass for 24 hours. After reaction

completion filtered the reaction mass to give crude 2-Methyl-2-amino-3-chloropropanoate

hydrochloride. The crude is crystallized in methanol. Filtered it and dried it to give white solid 2-

Methyl-2-amino-3-chloropropanoate hydrochloride.



Figure 2.30 :Process flow diagram

Material balance of Methyl – 2- amino – 3 – chloropropionate HCL

STAGE 1

INPUT OUTPUT


Serine MT 0.3019 Serine methylester MT 0.4470

Thionyl Chloride MT 0.3452 Hydrochloric Acid MT 0.1048

Methanol MT 0.0919 Sulphur Dioxide MT 0.1838



STAGE 2

INPUT OUTPUT


Serine methylester MT 0.4470 Methyl-2-amino-3-

chloropropinate HCL

MT 0.5000

Thionyl Chloride MT 0.3452 Hydrochloric Acid MT 0.1048

Water MT 5.0000 Sulphur Dioxide MT 0.1838

Water MT 5.0002


2.6.30. Manufacturing Process of 2-(2-(Aminothiazole-4-yl)-2-[2-(terbutoxycarbonyl)

isopropoxyimino] acetic acid (ATTBA) Ceftazidime

Stage-I.



Charged toluene as asolvent in reaction vessel. Charged Ethyl-2-(2-aminothiazol-4-yl)-2-

(hydroxyimino) acetate (ATHA) and potassium carbonate.Heat the reaction mass. After reaction

completion filter the reaction mass. Distilled out toluene from filterate and stripping with ethanol

to give stage-I.

STAGE – II Formation of ATTBA

Stage-II.

Charged ethanol into reaction vessel. Charged stage-I into it followed by slowly addition of aq.

KOH. Reflux the reaction mixture under stirring. After reaction completion adjust pH of the

reaction mass with dil.

Hydrochloric acid.Filtered the reaction mass and dried it to give white crystal of 2-(2-

Aminothiazole-4-yl)-2- [2-(tert-butoxy carbonyl)isopropyl imino]acetic acid (ATTBA).


Material balance of 2-(2-(Aminothiazole-4-yl)-2-[2-(terbutoxycarbonyl) isopropoxyimino]

acetic acid (ATTBA) Ceftazidime

STAGE 1

INPUT OUTPUT


ATHA MT 0.1631 Di-ester MT 0.2712

BIBT MT 0.1710 Hydrogen Bromide MT 0.0610

Potassium carbonate MT 0.1047 Potassium Iodide MT 0.1260

Potassium Iodide MT 0.1260 Potassium

Hydroxide

MT 0.0420

N-N

Dimethylformamide

MT 0.0550 N-N

Dimethylformamide

MT 0.0550

Water MT 5.0136 Potassium Hydrogen

Carbonate

MT 0.0750

Water MT 5.0168




STAGE 2

INPUT OUTPUT


Di-ester MT 0.2712 ATTBA MT 0.2500

Sodium Hydroxide MT 0.0306 Methanol MT 0.0240

Methanol MT 0.0240 Sodium Chloride MT 0.0440

Hydrochloric Acid MT 0.0270 Iso Propyl Alcohol MT 0.0450

Iso Propyl Alcohol MT 0.0450 Ethanol MT 0.0340



2.6.31. Manufacturing Process of 2-chloro-3-cyanopyridine Mirtazipine intermediate

Stage-01: Methanol is charged in reaction vessel. Charged 3-cyano pyridine to it. Slowly add

acetic acid followed by addition of hydrogen peroxide. Reaction mass is stirred and refluxed for

few hours. After reaction completion distill off methanol & acetic acid, unload oily residue as

stage-01 material i.e. 3-Cyano pyridine-N-oxide.

Stage-02: Chloroform & stage-01 material is charged to reaction vessel followed by addition of

phosphorous oxy chloride under stirring. Reaction mass is refluxed and after reaction completion

temperature is brought to room temperature, solvent along with unreacted POCl3 is distilled off &

pH of reaction mass is adjusted to 9-10 using aqueous sodium hydroxide. Solid thus formed is

filtered. 2-Chloro-3-cyano pyridine is purified using crystallization with MDC and dried it.

Metaphophoryl chloride shall be generated as a by product and sell to authorized dealer.


Material balance of 2-chloro-3-cyanopyridine Mirtazipine intermediate

STAGE 1

INPUT OUTPUT




3-Cyanopyridine MT 0.1877 3-Cyanopyridine-N-

oxide

MT 0.2166

Hydrogen peroxide MT 0.0619 Water MT 2.0330

Water MT 2.0000


STAGE 2

INPUT OUTPUT


3-Cyanopyridine-N-

oxide

MT 0.2166 2-Chloro-3-cyano

pyridine

MT 0.2500

Phosphorous oxy

chloride

MT 0.2793 Metaphophoryl

chloride

MT 0.1795

Sodium Hydroxide MT 0.0736 Sodium Chloride MT 0.1055



2.6.32. Manufacturing Process of 4'-methyl-2-cyanobiphenyl (OTBN)

Stage-01: A solution of p-tolyl magnesium chloride in THF is charged reaction vessel under

nitrogen atmosphere at room temperature followed by o-bromobenzonitrile. After stirring reaction

mixture is hydrolyzed 1N hydrochloride solution. After extracting with ethyl ether, the organic

phase is dried over potassium carbonate, filtered and then evaporated under vacuum. Purified

OTBN using ethyl acetate Filtered it and dried it. White colour dry powder obtained. Mangesium

chloride bromide shall be generated as a by product and sell to authorized dealer.


Material balance of 4'-methyl-2-cyanobiphenyl (OTBN)

STAGE 1

INPUT OUTPUT


p-

tolylmagnesiumchloride

MT 0.7803 o-tolylbenzonitrile MT 1.0000

o-Bromobenzonitrile MT 0.9502 Magnesium

chloridebromide

MT 0.7210





2.6.33. Manufacturing process of m-Phenoxybenzaldehyde

Stage-I.

Benzaldehyde reacted with bromine and chlorine in presence of Aluminum Chloride, Ethylene di

chloride as a solvent in above reaction, the Brominated mass quenched in water and washed.

After washing organics mass is distilled and recovered ethylene di chloride is reused in

bromination. Distilled metabromo benzaldehyde taken for second stage. Distilled metabromo

benzaldehyde taken for second stage and Poly Aluminium Chloride to sale to paper industries for

paper sizing.

Stage-II.

Metabromo benzaldehyde reacted with Mono Ethyl Glycol and produce Meta bromobenzalacetal,

This metabromobenzalacetal react with KOH and phenol in presence of Toluene Solvent and

produce meta phenoxy benzalacetal which on hydrolysis with Sulphuric acid and water give meta

phenoxy Benzaldehyde and MEG water is neutralized with caustic lye and recovered water and

mono ethylene Glycol is recycle in next batch. Potassium bromide, hydrobromide are generated

as a by product and sell to authorized dealer. HCL is also generated as a byproduct which shall

be use in other products.


Material balance of m-Phenoxybenzaldehyde

STAGE 1

INPUT OUTPUT


Benzaldehyde MT 1.6060 3-

Bromobenzaldehyde

MT 2.8000

Bromine MT 2.4430 Aluminium

Hydroxide

MT 1.1800



Aluminium Chloride MT 2.0180 Hydrochloric Acid MT 1.6572

Water MT 2.8172 Hydrogen Bromide MT 1.2244

Water MT 2.0226


STAGE 2

INPUT OUTPUT


3-

Bromobenzaldehyde

MT 2.8000 m-phenoxy

benzaldehyde

MT 3.0000

Phenol MT 1.4387 Potassium Bromide MT 1.8000

Potassium Hydroxide MT 0.8475 Water MT 2.2862

Water MT 2.0000


2.6.34. Manufacturing process of 4-aminobenzamide

Stage-01: MDC is charged to the reaction vessel. Then 4-amino benzoic acid is charged to it

followed by addition of thionyl chloride at room temperature. After this quenched the reaction

mixture with water. Separate organic layer and aqueous layer.

Stage-02: transfer organic layer of stage-01 into reaction vessel. Add ammonia solution slowly.

Distill off solvent completely, solid thus formed is filtered. 4-amino benzamide is purified by

crystallization using methanol and dried as stage-02 i.e. 4-amino benzamide. HCL is also

generated as a byproduct which shall be use in other products.




Material balance of 4-aminobenzamide

STAGE 1

INPUT OUTPUT


4-Aminobenzoicacid MT 2.0145 4-Aminobenzoyl

chloride

MT 2.2854

Thionyl chloride MT 1.7650 Sulphur Dioxide MT 0.9410

Water MT 2.0000 Hydrochloric Acid MT 0.5361

Water MT 2.0170


STAGE 2

INPUT OUTPUT


4-Aminobenzoyl

chloride

MT 2.2854 4-Aminobenzamide MT 2.0000

Ammonia MT 0.2522 Hydrochloric Acid MT 0.5361



2.6.35. Manufacturing process of p-nitrobenzoyl chloride

Stage-01: Chloroform is charged to a reaction vessel followed by p-Nitro benzoic acid.

phosphorous penta chloride is added lot wise in reaction vessel at room temperature. The

reaction mixture is heated until the evolution of hydrogen chloride nearly ceases. After this

reaction mass is distilled to remove phosphorous oxychloride. The residue of 4- nitro benzoyl

chloride is purified by crystallization using MDC. Yellow needle like crystal obtained. Phosporus

oxy chloride is generated as by product which shall be sell to authorized dealer.HCL is also

generated as a byproduct which shall be use in other products


Material balance of p-nitrobenzoyl chloride

STAGE 1

INPUT OUTPUT


p-Nitrobenzoicacid MT 2.7018 p-Nitro benzoyl

chloride

MT 3.0000

Phosphorous penta MT 3.4000 phosphorous oxy MT 2.4789



chloride chloride

Water MT 5.0000 Hydrochloric acid MT 0.5897

Water MT 5.0332


2.6.36. Manufacturing process of Vanillin

Stage-I.

4-Hydroxybenzaldehyde reacted with bromine in presence of Aluminum Chloride, methane di

chloride as a solvent in above reaction, the Brominated mass quenched in water and washed.

Distill methane di chloride. 3-bromo-4-hydroxybenzaldehyde used in next stage and Poly

Aluminium Chloride to sale to paper industries for paper sizing.

Stage-II.

3-Bromo-4-hydroxy benzaldehyde reacted with sodium methoxide in presence of copper

bromide, ethyl acetate used as a solvent. Heat the reaction mass until reaction complies. Slowly

cool the reaction mass and filtered it. Vanillin is purified using chloroform. Sodium bromide and

hydrogen bromide are generated as by product which shall be sell to authorize dealer. HCL is

also generated as a byproduct which shall be use in inhouse DM plant.


Material balance of Vanillin

STAGE 1

INPUT OUTPUT


4-

Hydroxybenzaldehyde

MT 1.6055 3-Bromo-4-

Hydroxybenzaldehyde

MT 2.6420



Bromine MT 2.1220 Aluminium Hydroxide MT 1.0250

Aluminium Chloride MT 1.7530 Hydrogen Bromide MT 1.0636

Water MT 5.7099 Hydrochloric Acid MT 1.4390

Water MT 5.0208


STAGE 2

INPUT OUTPUT


3-Bromo-4-

Hydroxybenzaldehyde

MT 2.6420 4-Hydroxy-3-methoxy

benzaldehyde

MT 2.0000

Sodium Ethoxide MT 0.7171 Sodium Bromide MT 1.3527



2.7. DETAILS OF RAW MATERIALS, CONSUMPTION AND SOURCE

Each product is unique in nature and application/ use, process of manufacture and raw

material requirement. Raw material required along with estimated quantity, likely source of

material and mode of transport of raw material is mentioned in Table 2.4. The

transportation of raw materials will be done by road complying with all safety requirements

as per MSIHC rule.

The raw materials will be procured and stored / inventory will be maintained as per market

requirement of the products and production schedule. Some of the key raw materials are:

Table 2.4 : List of Raw materials, consumption and its source

S.No.

Raw Material

CAS NO LC50/LD 50 Qty in MT/Day

State Storage Capacity In MT

1. Acetic Acid

64-19-7 Inhalation, mouse: LC50 = 5620 ppm/1H. Oral, rat: LD50 = 3310 mg/kg. Skin, rabbit: LD50 = 1060 mg/kg

299.19 Liquid 552

2. Ethyl

Alcohol

64-17-5 LDL[Human] - Route: Oral; Dose: 1400 mg/kg LDL[Human child] - Route: Oral; Dose: 2000 mg/ kg LDL[Rabbit] - Route: Skin; Dose: 20000 mg/kg (Ethyl alcohol 200 Proof)

206.53 Liquid 4050

3. Para

Toluene

Sulphonic

Acid

104-15-4 Acute oral toxicity (LD50): 2840 mg/kg (Mouse)

0.192 Solid In Bags, Stored

in ware house



4. Iso Butyl Benzene

538-93-2 LD50 > 2000 mg/kg ( Rat )

29.56 Liquid 526

5. Acetyl Chloride

79-04-9 ORAL (LD50): Acute: 910 mg/kg [Rat].

17.32 Liquid 120

6. Iso Propyl Alcohol

67-63-0 ORAL (LD50): Acute: 5045 mg/kg [Rat]. 3600 mg/kg [Mouse].

16.2375

Liquid 46

7. Mono Chloro Acetic Acid

79-11-8 ORAL (LD50): Acute: 55 mg/kg [Rat]

20.85 Solid 120

8. Sodium

7440-23-5

- 5.162 Solid In ,Drums

stored in sodium room

9. Sodium Dichromate

10588-01-9

LD50 = 46 mg/kg ( Rat ).

65.75 Solid In Bags, Stored in ware house

10. Aluminium Chloride

7446-70-0

ORAL (LD50): Acute: 3805 mg/kg [Mouse.].: LC50: 100 mg/l/h

45.87 Solid In Bags ,Stored in ware house

11. Sulphuric Acid

7664-93-9

LC50 = 510 mg/m3 ( Rat ) 2 h, LD 50 oral 2140 mg/kg ( Rat )

23.43 Liquid 115

12. Acetic

Anhydride

108-24-7 LD50 oral rat 1780 mg/kg bodyweight , LC50 inhalation rat (mg/l) 1000 ppm 4h

41.93 Liquid 525

13. Chlorine

7782-50-5

LC50 (inhalation, rat) = 293 ppm/1 hour ,

30.86 Gas 164. Nos of

cylinder

storage

capacity store

in chlorine yard

14. Toluene

108-88-3 ORAL (LD50): Acute: 636 mg/kg [Rat]. ... VAPOR (LC50): Acute: 49000 mg/m 4 hours [Rat]

63.255 Liquid 260

15. Propylene


18.81 Gas 180

16. Potassium Carbonate

584-08-7 Acute oral toxicity (LD50): 1870 mg/kg [Rat].

15.93 Solid In Bags

17. Mono Methyl Chloro Acetate

96-34-4 LD50 = 107 mg/kg ( Rat ),LC50 = 210 ppm ( Rat ) 4 h

2.41 Liquid In Drums

18. 2,6 Dicholorop

87-65-0 Oral rat LD50: 40 mg/kg




henol

19. Aniline

62-53-3 ORAL (LD50): Acute: 250 mg/kg [Rat.].

2.07 Liquid In ,Drums stored in ware house

20. Chloro acetyl Chloride

79-04-9 Rat LD50 (oral) 208mg/kg


21. Sodium Methoxide



22. Sodium Hydroxide

1310-73-2

LC50 = 1200 mg/m3/2H; Inhalation, rat, LD50 = 6600 mg/kg; Oral, rat


23. Dicyandimide

461-58-5 Mouse LD50 (oral) 10 g/kg


24. Dimethylamine Hydrochloride

506-59-2 Acute oral toxicity (LD50): 1070 mg/kg [Rat


25. 4-chlorophenyl (4-hydroxyphenyl)-methanone

42019-78-3

0.4839 Solid In Bags ,Stored

in ware house

26. Chloroform

67-66-3 Acute oral toxicity (LD50): 36 mg/kg [Mouse].Acute toxicity of the vapor (LC50): 47702 mg/m 4 hours [Rat]. 3

5.56 Liquid 20

27. Acetone

67-66-3 Acute oral toxicity (LD50): 36 mg/kg [Mouse].Acute toxicity of the vapor (LC50): 47702 mg/m 4 hours [Rat]. 3

15.06 Liquid 55

28. 2-chlorophenyl glycine

67-64-1 Acute oral toxicity (LD50): 3000 mg/kg [Mouse]. Acute toxicity of the vapor (LC50): 44000 mg/m3 4 hours [Mouse]


29. Methanol

67-56-1 Acute toxicity of the vapor (LC50): 64000 4 hours [Rat].Acute oral toxicity (LD50): 5628 mg/kg [Rat]

7.236 Liquid 35

30. Ammoniu

1336- Acute oral toxicity 0.337 Liquid In ,Drums



m Hydroxide

21-6 (LD50): 350 mg/kg [Rat].

stored in ware house

31. Tartaric Acid

526-83-0 LD50 oral rat. > 2000 mg/kg.


32. 2 (thio pheny-2yl) ethanol

5402-55-1

0.3050 Liquid In ,Drums


33. 4-Methoxybenzene 1-sulfonyl chloride

98-68-0 0.4586 Solid In Bags ,Stored

in ware house

34. IPA.HCL 0.2323 Liquid In ,Drums


35. Paraformalehyde

30525-89-4

ORAL (LD50): Acute: 800 mg/kg [Rat]


36. Pthalic

Anhydride



in ware house

37. Monoethan

olamine

141-43-5 Acute oral toxicity (LD50): 700 mg/kg [Mouse]


38. Xylene 1330-20-

7

Acute oral

toxicity (LD50): 2119

mg/kg [Mouse]


39. 4-

chloroethyl

acetoaceta

te

638-07-3 LD50 = 200 mg/kg ( Rat )


40. Sodium

Hydride

7646-69-7

LD50 Oral>5000 mg/kg (Rat)


in ware house

41. N-N,

dimethylfor

mamide


0.0339 Liquid In Bags ,Stored in ware house

42. Hydrochlor

ic Acid

7647-01-0

Acute toxicity of the vapor (LC50): 3124 ppm, 1 hours [Rat]

3.287 Liquid 50

43. Hexane


21.231

8

Liquid 95

44. Orthochlor

o benz

89-98-5 LD50: Not available 0.0652 Liquid In Bags ,Stored

in ware house



aldehyde

45. Piperidine

110-89-4 LD50 = 337 mg/kg ( Rat )

0.0769 Liquid In Bags ,Stored in ware house

46. Methyl-3

amine

crotonate

14205-39-1

Oral rat LD50 : 1760 mg/kg.


47. 2-3

dichloro

benzonitril

e

6574-97-6


in ware house

48. Amino

Guanidine

bicarbonat

e

2582-30-1

Rat LD50. (intraperitoneal). 1160mg/kg


in ware house

49. 2 Benzyl

Pyridine

101-82-6 0.0700 Liquid In Bags ,Stored

in ware house

50. 2 chloro -

N-N

dimethyl

ethyamine

hydrochlori

de

6574-97-6


in ware house

51. Sodium

Amide

2582-30-1

Rat LD50. (intraperitoneal). 1160mg/kg


in ware house

52. Ibuprofen

101-82-6 2.35 Solid In carboys,

Stored in BSR

53. DL-Lysine

6574-97-6


in ware house

54. Cholic Acid

81-25-4 Oral LD50 (mouse): 4950 mg/kg


in ware house

55. Sodium

Hypochlorit

e

7681-52-9

Acute oral toxicity (LD50): 5800 mg/kg [Mouse].


stored in ware

house

56. Hydrazine 302-01-2 0.0205 Liquid In ,Drums

stored in ware

house

57. Potassium

Hydroxide

1310-58-3

Acute oral toxicity (LD50): 273 mg/kg [Rat]


in ware house

58. Hydrogen

gas

1333-74-

0

LC50 inhalation rat

(ppm) > 15000

0.0012 Gas In 7m3 /10 M3

cylinders store



ppm/1h

in separate

yard

59. Potassium

Tert

Butoxide

865-47-4 LD50 Oral 1650 mg/kg ( Rat )


in ware house

60. Triethylami

ne

121-44-8 Acute oral toxicity (LD50): 460 mg/kg [Rat.]


stored in ware

house

61. Dibenzo[b,f][1,4]thiazepin-11(10H)-one

3159-07-7


in ware house

62. Phosphorus Oxy-chloride

10025-87-3

ORAL (LD50):. Acute: 380 mg/kg [Rat]


stored in ware

house

63. Piperazinyl ethoxy ethanol

13349-82-1



64. Fumaric Acid

110-17-8

Acute oral toxicity (LD50): 10700 mg/kg [Rat]

0.3983 Solid In ,Drums stored in ware house

65. N-Octyl D

Glucamine

23323-37-7

0.7207 Solid In ,Drums


66. Cyclohexanone


2.8655 Liquid 10.00

67. Methylcyanoacetate

105-34-0 2.8933 Liquid 10.00

68. Ammonium acetate

631-61-8 Oral Rat LD50mg/kg: 736.


69. Cyclohexane


2.4573 Liquid 10.00

70. Dry HCl

7647-01-0

Acute toxicity of the vapor (LC50): 3124 ppm, 1 hours [Rat]

3.1972 Gas In 50 kg Cylinders, Store in separate yard

71. Raney-Ni

12635-27-7

LD50: Not available. LC50: Not available


72. Methylethylketone


5.0657 Liquid 20.00



73. Liq. Ammonia

7664-41-7

LC50 inhalation rat (ppm) 7338 ppm/1h


74. Di methyl sulphate

77-78-1 Acute oral toxicity (LD50): 140 mg/kg [Mouse]. Acute toxicity of the vapor (LC50): 45 ppm 4 hour(s) [Rat]


75. Di chloro methane

75-09-02 Acute oral toxicity (LD50): 1600 mg/kg [Rat]. Acute toxicity of the vapor (LC50): 52000 1 hours [Rat].

6.6056 Liquid 20.00

76. Hydrogen peroxide

7722-84-1

Acute OralLD50 Rat: 1253 mg/kg.


77. Thionyl chloride

7719-09-7

LD50 Oral - rat - 324 mg/kg


78. 5- di fluoro methoxy-2-mercapto benzimidazole

97963-62-7



79. 4-Methyl-2-cyanobiphenyl (OTBN)

114772-53-1



80. Dibromo Hydrantoin

77-48-5 Oral, rat: LD50 = 250 mg/kg;


81. hyflo 0.022 Solid In Bags ,Stored

in ware house

82. 2-Butyl-4-chloro-5-formyl-Imidazole

83857-96-9

LD50 = 980 mg/kg 0.4088 Solid In ,Drums


83. Sodium borohydride (NaBH4)

16940-66-2


0.1205 Solid In, Drums stored in ware house

84. Sodium Azide

26628-22-8

Acute oral toxicity (LD50): 27 mg/kg [Mouse]

0.1426 Solid In, Drums stored in ware house

85. Activated Carbon

7440-44-0

Acute inhalation is LC50 (RAT) is 64.4

0.081 Solid In, Drums stored in ware



mg/l house

86. Diphenyl(piperidin-4-yl)methanol

115-46-8 Acute Oral, mouse: LD50 = 650 mg/kg.


87. Methyl-2-(4-(4-chlorobutanoyl)phenyl)-2-methylpropanoate

154477-54-0

0.2850 Liquid In, Drums


88. Dimethylformamide


1.3946 Liquid In, Drums stored in ware house

89. Ethyl acetate

141-78-6

Acute oral

toxicity (LD50): 4100 mg/kg [Mouse]. Acute toxicity of the vapor (LC50): 45000 mg/m3 3 hours [Mouse]

3.7295 Liquid 1265.00

90. Sodium borohydride

16940-66-2



91. 2- Chlorobenzaldehyde

89-98-5 1.0978 Liquid In, Drums


92. Hydroxylamine sulphate

10039-54-0

LD50 = 842 mg/kg ( Rat ).


93. Methylacetoacetate

105-45-3 LD50 Rat oral 3.0 g/kg LC50 Rat inhalation >26.4 mg/L/1 hr

1.337 Liquid In, Drums stored in ware house

94. Triphosgene

32315-10-9


95. EDTA 10378-

23-1

Acute oral toxicity (LD50): >2000 mg/kg [Rat].


96. 2,6 – Dichlorobenza aldehyde

83-38-5 0.2419 Solid In Bags, Stored

in ware house

97. 2-cholro-6-fluorobenz aldehyde

387-45-1 0.2564 Solid In Bags, Stored

in ware house



98. m-Xylene

108-38-3 Acute oral toxicity (LD50): 5000 mg/kg [Rat.]

7.1600 Liquid 40.00

99. Oleic acid



100. Propanol 71-23-8

Acute oral

toxicity (LD50): 1870

mg/kg [Rat.]

11.76 Liquid 40.00

101. Piperazine

110-85-0 Oral (rat)LD50: 1900 mg/kg.


102. 2-(2-chloroethoxy) ethanol

628-89-7 LD50 Oral LD50 = 250 mg/kg ( Rat )


103. Serine

302-84-1 0.3019 Solid In Bags ,Stored

in ware house

104. Ethyl-2-(2-aminothiazol-4-yl)-2-(hydroxyimino) acetate (ATHA)

64485-82-1


in ware house

105. tert-butyl-2-bromo-2-methyl propanoate (BIBT)

23877-12-5



106. Potassium Iodide

7681-11-0


107. N-N Dimethylforamide



108. 3-Cyano pyridine

100-54-9 Acute Oral Rat LD50. = 1185 mg/kg


109. P-Tolylmagnesiumchlo ride

696-61-7 LD50 Oral=1215 mg/kg (Rat)


110. o-Bromobenzonitrile

2042-37-7



111. Benzaldehyde


1.6060 Liquid In ,Drums stored in ware



house

112. Aluminium Hydroxide

21645-51-2


113. Bromine

7726-95-6

ORAL (LD50): Acute: 3100 mg/kg [Mouse]


114. Phenol



115. 4-Amino benzoic acid

150-13-0 LD50 Oral - Mouse - 2,850 mg/kg


116. Ammonia

1336-21-6

Acute oral toxicity (LD50): 350 mg/kg [Rat].

0.2522 Gas 120 Nos of Cylinder in Ammonia yard

117. p-Nitro benzoic acid

62-23-7 ATEmix (oral) 1960 mg/kg


118. Phosphorous penta chloride

10026-13-8



119. 4-Hydroxy benzaldehyde

123-08-0 LD50 Oral - Rat 2,250 mg/kg


120. Acetonitrile

75-05-8

Acute toxicity of the vapor (LC50): 7551 8 hours [Rat.]


121. Triethylene glycol



122. THF

109-99-9 ORAL (LD50): Acute: 1650 mg/kg [Rat]. VAPOR (LC50): Acute: 21000 mg/m 3 hours [Rat]


123. N-butanol

71-36-3 ORAL (LD50): Acute: 790 mg/kg [Rat.]

6.40 Liquid 30

All solid / powder / granular raw materials will come in bags / drums and will be

transported through road transport. Liquid raw materials will come in road tankers (bulk) or

in drums through road. Most of the raw materials are indigenously available.

Products are changed as per market demand. The solid raw materials in bags will be

stored in Godown with adequate safety measures.



2.7.2. Raw Material Storage (Liquids)

IOLCP is having a long list of raw materials some of which are hazardous in nature

(inflammable, explosive, highly reactive and toxic). These materials are to be stored with

full safety and security. Some of the materials will be stored in Tank.

2.8. INFRASTRUCTURE & UTILITIES REQUIRED FOR THE EXPANSION PROJECT

2.8.1. Land

Expansion of the proposed project will be done in existing premises. The land break-up

mentioned in Table 2.6.

Table 2.5 : Area Breakup

S. No. Area Description Existing

After Proposed Expansion

Remarks

(Sq.mtr) (Sq.mtr)

1 Production plants including ware house, utilities

48863.42 70952.42

2 Administration, QC, R&D, HSE, Security and welfare facilities

2217.97 2268

3 Open Areas, Roads, Pathway & Auxiliary

56645.57 53763.53 Open area to be used for production blocks , Future Expansion etc

6 Scrap yards 1765.45 1765.45

7 Green belt/Plantation 97124.8 121404.8

206617.21 250154.2 (Source:IOLCP)

2.8.2. Water

Water requirement will be mainly for process, washing, scrubber, boiler, cooling and

flushing. In addition, water will also be required for gardening and sanitary purposes.

Water requirement for the proposed project after expansion is 1800 KLD source through

bore well/surface water.

Total water requirement–1800 KLD (Fresh water 1456 KLD and Recycle water 344 KLD)

Fresh water requirement for existing unit -900 KLD

Fresh water requirement for expansion unit - 900 KLD

Recycled water - 344 KLD

Table 2.6 : Water Breakup

Input Output

Particulate Water Consumption KL/Day (first day)

Recycled KL/Day

Loss Effluent

Process 755 00 00 625 (Low TDS to ETP) 130 (High TDS to MEE)

Boiler 295 142 77 76 (to ETP)

Cooling tower 615 202 413



{148 (from MEE

condensate)

54 (from UFRO)}

Washing 50 0 0 50 (To ETP)

Domestic 85 0 12 73 (To ETP)

Total 1800 344 502 954

(Source: IOLCP)

Figure 2.1: Proposed Water Balance (After expansion)



Cooling Water System

Induced type Cooling Tower of adequate capacity for the process cooling shall be

provided.

Chilled Water / Brine Plant

In order to control / maintain low process temperature chilled water system) and

chilled brine system has been provided.

2.8.3. Power

Proposed unit have its own 13 MW & 4 MW Power cogeneration plant. There is no

addition of power plant existing power plants are sufficient to cater the upcoming

project. Additionally, 2 X 1000 KVA and 1 X 625 KVA DG sets are available for

existing project. For the proposed expansion project additionally one D.G. Sets of

capacity 1 X 1000 KVA will be installed for power-backup (as a standby).

2.8.4. Boiler

Proposed unit have three boiler capacity of 14 TPH, 32 TPH and 80 TPH, there is no

addition of new boiler for the proposed expansion project.

2.8.5. Fuel

Husk used in boiler (capacity of 14 TPH, 32 TPH and 80 TPH), HSD will be used in

DG Sets. Fuel (coal) consumption in the plant is as given below:

Table 2.1: Fuel Consumption

S.No Stack attached to Fuel Fuel consumption per Hour

APCM

1 Boiler 14 TPH Husk 3.75 TPH Trema Cyclone

2 Boiler 32 TPH Husk 8.5 TPH ESP

3 Boiler 80 TPH Husk 21 TPH ESP

4 Furnace 1500000 KCal/Hour

Diesel 150 Ltr/hr Adequate Stack Height

5 Furnace 2000000 KCal/Hour 2 Nos


6 Furnace 200000 x 5 Nos Kcal/hour


7 DG set 3 X 1000 KVA Diesel 208 Ltr/hr Adequate Stack Height

8 DG set 625 KVA Diesel 125 Ltr/hr Adequate Stack Height



2.8.6. Man Power

The project is intended to use skilled manpower. Total manpower for the proposed

project is expected 1850 Persons . For the existing unit 1200 person were employed.

Plant is expected to generate addition 650-person employments directly or indirectly.

Company will give preference to local people for employment.

2.8.7. Facilities for worker

Company will give preference to local people (Skilled People) for employment.

Company is more concern for the safety and health of its people, including the larger

community outside of the company and the environment as a whole. Hence IOLCP

have its own medical dispensary with reputed doctor for routine health checkup at site.

All employees will be trained to work on sites in the safest possible manner and shall

be made aware of the consequences of unsafe act. Company will also provide the

shelter, safe drinking water, sanitation facility. The company has also allocated

adequate budget for improving the safety and on initiatives to enhance the safety and

health of employees.

2.8.8. Wastewater treatment:

The waste water generation is from process utilities and domestic purposes. Below

table summarizes section wise generation of waste and mode of treatment

Effluent pH TDS (mg/l) COD (mg/l) Treatment Flow

HTDS/

HCOD

2 to 12 >5000 -<100000 >5000 -<30000 Send to MEE ATFD

MEE condensate to Cooling Tower

LTDS /

LCOD

6-10 < 2000 <3000 - < 5000 Collection Equalization Tank Neutralization Tank Two stage Anaerobic tank Aerobic tank Secondary clarifierPressure Sand Filter Activated Carbon Filter For plantation.

Domestic 6-9 < 3000 < 3000 ETP/STP

Effluent Characteristics

Effluent generated from process, utilities and sewage which will be treated through

ETP of capacity 1000 KLD.proposed expansion will be carried out in existing unit and

online monitoring system is also installed, Punjab pollution control board has done the

sampling and monitoring, the copy of result is enclosed as Annexure XII. The inlet &

outlet characteristics of effluent are shown below

S.No Parameters Inlet of ETP Outlet of ETP Aeration

1. pH 6.9 7.9

2. Total Suspended

Solids (mg/l)

98 32



3. Chemical Oxygen

demand (mg/l)

1840 122

4. Bio-Chemical

Oxygen demand

(mg/l)

410 24

5. Phenolic

compound (mg/l)

BDL BDL

6. Phosphate (mg/l) 0.4 0.1

7. Sulphide (mg/l) 1.2 BDL

8. Lead (mg/l) BDL BDL

9. Mercury (mg/l) BDL BDL

10. Cyanide (mg/l) BDL BDL

11. Arsenic (mg/l) BDL BDL

12. Total Chromium 1.07 BDL

13. Bio – assay - 90% survival of

fish in

100%effluent

after 96 hrs

14. Oi and Grease 8.6 BDL

15. Mixed Liquid

Suspended Solids

(mg/l)

- - 4460

16. Mixed Liquid

Volatile

Suspended Solids

(mg/l)

- - 3340

Source: Quaterly sample report PPCB_date 26.06.2018

Note: BDL means Below Detection Limit

Effluent Treatment Plant (ETP): Capacity of 1000 KLD

Treatment of LOW TDS Low COD and High TDS High COD

Effluent of Industry is segregated in to two Streams.

(i) Low TDS and Low COD

(ii) High TDS and High COD

Low TDS and Low COD Effluent Treated in ETP. Effluent treatment plant having 1000

M3 capacity per day and the scheme for treatment of low dissolved solids waste

waters is biological comprising of four stages – two stages anaerobic and one stage

aerobic followed by tertiary.

The units are:

1. Bar Screens-Grit Chamber.

2. Neutralization

3. Equalization Tank.

4. Anaerobic Filter Stage-I



5. Anaerobic Filter Stage-II

6. Aerobic Reactor.

7. Secondary Sedimentation Tank.

8. Sand Filtration

9. Carbon Contractor

10. Sludge Dewatering.

Wastewaters flow under gravity from various sections into the equalization tank

through the bar screens and grit chamber. The bar screens arrest the floating debris,

like wood, rags, plastics, etc. and the grit chambers settle out the grit, sand, etc.V-

notch plates and Magnetic Flowmeter is provide data the outlet of the effluent

treatment plant for measurement of flow.

The pH of the influent to the treatment plant is acidic in nature most of the time.

Therefore, neutralization done by addition of alkali - sodium hydroxide to raise pH from

5 to between 6.8 and 7.2.

An equalization tank of forty-Eight hours capacity at peak flown provided to take care

of varying pollution loads discharged by the industry. The effluents shall then be lifted

with pump(s) from the equalization tank into a two-stage anaerobic filter system

provided in series.

Each anaerobic filter consists of a reactor filled with coarse inert graded packing

media. The wastewater enters at the base of the reactor through the under drainage

system and flow upwards through the filter bed. Anaerobic organisms shall

accumulate in the voids of the media as well as become attached to the media

surfaces. The waste thus, come into intimate contact with a large active biomass as it

passes through the reactor. Provision also made for effluent recycle to the filters to

achieve good mixing, optimum up flow velocities, reducing alkali & nutrient

requirements.

The effluent from the anaerobic stage be further treated for removal of Carbonaceous

BOD in a complete mix activated sludge reactor. The process has the capacity to hold

a high MLSS level in the aeration tank imparting increased Operational stability at

shock organic loadings.

The waste waters are deficient in nutrients especially nitrogen. This deficiency made

good by addition of DAP and Urea into each of the biological stages of treatment as

per requirement. Diffused aeration employed to maintain the desired DO level and

adequate mixing of liquor in the reactor. The mixed liquor from the aeration tank flow

in to the secondary sedimentation tank for separation of biomass.

The settled sludge from the sedimentation tank bottom lifted with the help of sludge

pump and re-circulated back into the aeration tank for reseeding. The surplus sludge

from aerobic stage pumped onto the sludge drying beds for Sun drying.

The overflow from the secondary sedimentation tank filtered through sand to remove

the organics associated with the suspended solids present in the secondary effluent.

This also prevent high influent suspended solids concentrations to enter and form

deposits on the carbon granules which otherwise result in pressure loss, flow



channeling, blockages and loss of adsorption capacity. Small doses of flocculants

alum/PAC added to improve filter efficiency. The filtered waste waters shall be

contacted with granular activated carbon for removal of toxic compounds.

The waste waters after carbon contact shall conform to the standards prescribed by

the Punjab Pollution Control Board discharged onto land for irrigation and gardening

High TDS is Treated in Multi Effect Evaporator having capacity 200 KL/Day . In High

TDS Concentrated Stream High TDS High COD taken in to Multi Effect Evaporator,

Where condensate of Multi Effect Evaporator is reused in Cooling Tower and solid

recovered as ( by product) that is sale in market or send to TSDF.



Figure 2.38 : Flow diagram of ETP



2.8.9. Multiple Effect Evaporator

The MEE will be three-effect configuration with Thermal Vapor Compressor. A

Mechanical compressor can be offered as well, but due to low steam cost and

consumption, a TVR-based system is considered as optimum. All three calandria to be

configured as forced circulation systems to minimize scaling. The final effect will have

a salt settler, and the slurry from bottom of the settler shall be dewatered in a Basket

Centrifuge to provide wet salt with just 10-15% moisture, which will be packed in

HDPE bags/drums and disposed to approve landfill. The MEE diagram given in figure.



Figure 2.39 Flow Diagram of MEE



2.9. SOLVENT MANAGEMENT SYSTEM:

Solvent Recovery Measures:

IOLCP has a well-defined Solvent Recovery system. The existing solvent recovery is

98 %.

Process Steps for solvent recovery:

All the solvents as above are/ shall be recovered from reaction vessels

Each reaction vessels are shall have overhead condenser (primary and a vent

condenser)

The primary condenser shall have the utility connection of either cooling water (32-

37°C) or chilled water (5-10°C) or both.

The vent condenser is/shall have a utility connection of either chilled water (<7°C) or

brine (-15 to-20) or both.

By these measures the utilities in the condensers are/ shall always be below the

condensing temperature of various solvents and there for least vapor pressure or mole

fraction at condensing temperature.

Unit is/shall be using steam ejector for vacuum creation.

Each vacuum device is/shall also have a knockout pot and a condenser after suction

of the vacuum pump.

The reactor and solvent handling pumps is/shall have double mechanical seal/seal

less pumps to prevent leakages. Also, tank is/shall be provided with breather valve to

prevent losses.

Solvent is/will be taken from storage tank to reactors through closed pipe line. The

Storage Tank is/shall be vented through trap receiver & condenser operated on

cooling water.

The condenser is/shall be provided with sufficient HTA and residence time so as to

prevent any loss of solvent.



Figure 2.40 : Solvent Recovery Process



2.10. AIR EMISSION AND AIR POLLUTION CONTROL MEASURES

Gaseous emission from fuel burning, consist of common pollutants like SO2, NO2, and

PM would be discharged into atmosphere through Stack of suitable height.

Unit has existing green belt of 30 acres (45% of the total plot area) which shall be remain

same after expansion.

The drying of the product is done in a closed type continuous Fluidized Bed dryer/ Nudge

filter to avoid the exposure of any chemicals to human being.

Adequate systems shall be provided to capture the emissions from process plants &

maintain the emission quality as per recommended guidelines with central scrubber

having caustic solution, before venting it in to the atmosphere.

Fuel combustion: - The combustion are from DG sets and boiler etc. By controlling

optimum conditions and attached with ESP and proper stack height kept the emission

within prescribed limit.

Process vents: The Pollutants normally from various processes are HCl, Cl2,and

SO2etc. Caustic/ acid/ water scrubbers shall be provided to control process emissions.

The point sources of emissions from the project are boilers, DG sets and Process

reactors. Fugitive emission sources are from material handling systems. Table 3.12

below quantifies emissions different sources.

Table 2.7 Stacks in the API Plant with emission details

S.

n

Description Ht.

(m

)

Dia.

(m)

Vel.

(m/s

)

Tem

p

(0C)

Flow

Rate

Emission rate

(g/s)

nM³/hr SP

M

NO

x

HCL

1 boiler 14 tph 52 1.3

5

5.73 75 25271.5

2

1.05 2.11 -

2 boiler 32 tph 60 1.5 12.2 80 65487.1

5

2.73 5.46 -


5

6.7 85 48267.6

7

2.01 4.02 -

4 Furnace 1500000 Kcal/hr 28 0.5 5 200 2225.55 0.03 - -

5 2 X Furnace 2000000 Kcal/hr 24 0.5 2 200 890.22 0.01 - -

6 5 X Furnace 200000 Kcal/hr 16 0.2

5

4.3 200 478.49 0.01 - -

7 IBAP Scrubber 16 0.2

5

4.3 35 478.49 0.01 - 0.00

8 Acetyl Scrubber 16 0.25

4.3 35 478.49 0.01 - 0.001

9 PAC Scrubber 16 0.25

4.3 35 478.49 0.01 - 0.001

10 M-phenoxybenzaldhyde/Vanillin/ATTBA/Losatan potassium/ Methyl – 2- amino- 3 – chloro propionate HCL/ 4 amino benzamide/P-nitrobenzyl chloride

16 0.25

4.3 35 478.49 0.01 - 0.001



Control of fugitive emission

Fugitive emissions are expected to be generated during construction and operation

stages of the proposed project. During construction stage, main source of fugitive

emission is dust which is expected mainly due to movement of vehicles carrying

construction material and vehicles used for construction. During operation stage, leakage

through valves, pumps, emission from open drum containing chemicals, open feeding;

storage tanks, etc. are the major sources of fugitive emissions of organic chemicals and

VOCs. Excess use of solvent may also result fugitive emission from the process vessels.

Following measures will be adopted to prevent and control fugitive emissions:

Airborne dust at all transfers operations/ points will be controlled either by

spraying water or providing enclosures.

Care will be taken to store construction material properly to prevent fugitive

emissions, if any.

Adequate ventilation will be provided.

Regular maintenance of valves, pumps and other equipment will be done to

prevent leakages and thus minimizing the fugitive emissions of VOCs.

Entire process will be carried out in the closed reactors with proper maintenance

of pressure and temperature.

Periodic monitoring of work area will be carried out to check the fugitive emission.

Breather valves will be provided on solvent tanks.

Solvent tank vents will be connected to vent chillers.

To eliminate chances of leakages from glands of pumps, mechanical seal will be

provided at all solvent pumps.

During transfer of material, steps shall be taken to reduce and prevent splashes

and spills. Any liquid or dry material spilled shall be cleaned as expeditiously as

possible.

Stand by pumps will be provided on all scrubbers. Besides, scrubbers will be

equipped with on-line pH meter for better operational control.

Close feeding system will be provided for centrifuges. Centrifuge and filtrate tank

vents will be connected to vent chillers.

Product filling stations will be equipped with vacuum duct hoods.

Good housekeeping, proper maintenance and continuous observation will

prevent the chances of any fugitive emission from the process plant.

When monitoring results indicate VOC above permissible limit repairing should be done

immediately. The repair should be conducted in such a way that there is no fugitive

emission from the particular component.

VOC Reduction Measures



Optimization of process parameters.

Change in utility services

Recycle / Reduction of Aqueous layer

Increase in settling time

Yield improvement

Stripping of Aqueous layer

Solvent input quantity reduction

Elimination of solvent wash

Common venting systems with spiral HEs

Ejectors replacement by Vacuum Pumps to capture VOC emission through open

ejector sumps

Vent Gas transportation from plants and treatment of the same in Incinerator

20 mbar nitrogen blanketing system in place

Vents of entire plant storage vessels, reactors condensors and any other

equipment are connected to a common header

Common header maintains 3-4 kg nitrogen pressure

When any solvent/reaction mixture is transferred from one equipment to other

equipment then Vapors displace from destination vessel and fill in the space

vacated in the source vessel not allowing any solvent vapors to escape

Secondary condensers are used in case of volatile solvents where chilled water

or chilled brine is used as a coolant

Vent line condenser after 3-4 kg nitrogen pressure header with suitable coolant to

trap volatile solvent

Instrumentation to prevent/control accidental/more release of solvent into the

atmosphere

Mechanical seal/seal less pumps are used for solvents

In unit operations/processes involving vacuum, vacuum is controlled by recycle of

vent gases from vacuum pump vent line

Instrumentation to prevent loss of solvent vapors (High vacuum trip with steam

block valve/feed block valve as the case may be)

Storage tanks and plant tanks are connected to same venting system. So no

escape of solvent during transfer

Appropriate design of condensers during detailed engineering phase of project.

(ensuring sufficient line size and thereby flowrate)

Annual cleaning of condensers to remove scaling (shutdown activity)

Storage of volatile liquids at lower temperature than boiling point to avoid losses

into the atmosphere. (Brine is used for the same)



Annual inspection and maintenance of scrubber. (Internals like distribution plate,

packings, spray nozzles etc.)

2.11. NOISE

The proposed project will have various machines and equipment‘s which will generate

noise. The equipment‘s and machines will have adequate provision to minimize the noise

generation. As per existing practice personnel working in the noisy area will be provided

with appropriate PPES. The person working in high noise area is undergone audiometry

examination once in a year.

Installation of the plant machinery will be done after- due consideration to design noise

levels and noise mitigation measures.

The green belt developed helps in reducing noise levels generated due to plant

operations.

There will be no major sources of industrial noise; minor noise generated from the

industrial operations will be controlled by proper maintenance.

Proper mitigation measures will be taken in addition to above for the reduction of noise

levels i.e. use of acoustic enclosures and providing personal protective equipment etc. to

the workers.

Periodical monitoring for noise is being carried out on regular basis.

Proper maintenance, oiling and greasing of machines at regular intervals is done to

minimize generation of noise at source.

2.12. HAZARDOUS WASTE MANAGEMENT

The hazardous waste is generated at various stages of the manufacturing activity. The

mode of disposal is mentioned for each category of waste as per hazardous wastes

(management, handling and transboundary movement) rules, 2016.(As specified under

hazardous wastes / management handling rules 1989) amendment rule 2003.

a. Process wastes/ residue

b. Chemical sludge containing residue

c. Date expired and off-specification drugs

All above waste are will be collected and stored at separate identified place and suitably

disposed off to authorized agencies.

Table 2.8 : Hazardous waste details S.No

Type of Waste

Category ( As per Schedule)

Existing Quantity (TPA/KLA)

(After Expansion Qty) TPA/KLA

Source of Generation

Mode of Storage

Mode of Treatment and Disposal

1 ETP Sludge

35.3 5.160 TPA 8.860 TPA From Effluent Treatment Plant

Stored in Hazardous Waste room in Environmentally Sound Manner

Sent to Authorized Dealer for Disposal



2 Distillation Residue

28.1 5.820 TPA 30 TPA From Distillation



3 Mobile Oil 5.1 0.450 KL 0.840 KL From Periodic Service of DG sets


Sale to Authorized Recyclers

4 Spent Catalyst

28.2 Nil 1.200 TPA Catalyst Residue


Send to TSDF facility

5 Date Expired Products

28.5 Nil 0.500 TPA Products after Expiry


Send to TSDF facility

6 Empty Barrels/Containers/Liners Contamined with Hazardous Chemicals/Waste

33.1 Nil 36.500 TPA Raw Material Empty Bags


Sale to Recyclers

7 Contaminated Cotton Rags or other Cleaning Materials

33.2 Nil 0.240 TPA Contaminated Cleaning Cloth/ Oil Soaked Cloth



8 Spent Carbon or Filter Medium

36.2 Nil 0.600 TPA From Filter Material, Spent Carbon



9 MEE Sludge

37.3 92.4 212 From MEE Stored in Hazardous

Waste room in

Environmentally Sound Manner




(Source:IOLCP)

2.13. AUXILIARY & GENERAL WELFARE FACILITIES

The following facilities have been considered under this head.

2.13.1. Fire and Safety System:

Site has full-fledged fire and safety system. Site has on-site emergency plan to get the

direction in case of emergency.

The fire and safety system shall be including:

Fire pumps (with emergency power from DG set) – 1 no. including 1 nos. jockey

pump, 1 nos. diesel driven, 1 no‘s electric pumps.

Water reservoir available for firefighting controlling

Full-fledged Emergency control centre

Fire hydrants

Other firefighting equipment including:

2.14. OHS System

IOLCP has well-organized Safety Management system with well defined ―Safety Health

& Environment Policy‖, ―Quality Policy‖. For the proposed expansion project, IOLCP is

committed to the principles of sustainable development. As a part of this commitment,

IOLCP protects the environment in which they operate and ensure the health and safety

of our employees, contractors, visitors and communities. All employees are responsible

for being aware about safety, health and environment needs in their area of work. The

proposed plant will also have these policies in place. The significance of safety & health

in chemical industries has been a vital issue in achieving productivity and an edge in

competitive world. Hence, all the pollution control measures envisaged at feasibility stage

will be implemented with due care.

The proposed plant will be designed as per guidelines comprising of separate entry &exit

for workers and material. The layout of plants will be under purview of various statutory

regulations and these regulations will be reviewed regularly. All reaction vessels will

relate to scrubber so that any toxic fumes/ vapor generated during reaction gets

neutralized.

The proposed plant will have Air Handling Units to keep temperature <25 deg in powder

processing area and filtered air will be supplied in other areas. Dust collector will be

provided in powder processing area to remove dust generated during sifting/ milling of

product. Workers engaged in powder processing work will be provided personal

protective equipment‘s like dust masks, respirators etc.

The proposed plant will be provided with sophisticated instrumentation for continuously

monitoring of operating parameters.

The plant premises will be strictly maintained as a ―NO SMOKING ―area. Firefighting

facility will be provided at site consisting of underground fire hydrant system and various

fire extinguishers.



For electrical instrumentation and installations, the entire plant will be sub divided into

hazardous and nonhazardous zone. In the hazardous zone, flameproof fittings &fixtures

will be provided. Arrangements will be made in each equipment to avoid static spark.

All reaction vessels will be provided safety valve, rupture disc, pressure gauges etc to

avoid any explosion. Provision for inert gas purging will be there in each reactor to avoid

possibility of developing any hazardous mixture.

The company will have On Site Emergency Plan to handle any emergencies e.g. fire,

chemical spillage and medical arising from any unforeseen reason.

Workers will be trained & make them aware regarding safety and proper hygiene in plant.

All workers will undergo periodic medical examination and will be provided personal

protective equipment‘s for their safety.

Major hazards can be avoided by proper implementation of Maintenance and Inspection

Schedule, Periodic maintenance will be in place to check the various types of

compressors, pumps, fan, and blowers and monitor the vibration level. Compliance of

Statuary Regulations related to Factory act and IBR in which all boilers will be hydro

tested all pressure vessels will be tested for ultrasonic thickness measurement and weld

joint by radiography. All hot/cold surfaces will be insulated. Waste generated during

process will be removed regularly. Proper housekeeping in maintenance block, utility

block will be done to ensure that spillage of oil, litters of maintenance material are

cleared off.

2.15. PROJECT COST ESTIMATES & IMPLEMENTATION SCHEDULE

This is a tentative schedule in which flexibility can be exercised depending upon the

market demand. Estimated project cost along with analysis in terms of economic viability

of the project.

Cost of Estimates of the Proposed Project is 205 crores. Project work will be start after

getting the environmental clearance.

2.16. CSR Activities

Unit has committed to spend about Rs. 1.53 crores (0.75% of the capital investment)

towards CER. But the Approved TOR is for 2.5 % of the project cost and IOLCP follow

the OM issued on dated 1st May 2018, hence earmarked the fund of Rs 1.53 crores. The

amount will be spending in next 3 years for infrastructure development of surrounding

area. Need based survey has been conducted in surrounding villages of the study area

and following facilities will be carried out and it will be continued for proposed expansion

project.

Allocation of funds for Public Development

Providing Bags of sugar to Jangham

Sponsor a child at CRY

Provide education expenditures for the physically disable persons i.e. deaf and

dumb ―Ek Prayas‖ and ―Govind Dham‖

Donation to schools such as Sacred Heart Convent School

Distribution of free medicines to the poor in nearby villages.



Misc. benefit like providing cash to poor students.

Celebrate Environment Day at Govt High School Village, Handiaya

Distribute Trees to peoples of Govt High School, Handiaya

Donation to NGO for Kedarnath Tragedy

Distribute Blankets and cloths Civil, Hospital, Ludhiana

Celebrate Children day at Govt High School, Longowal

Initiatives taken towards social commitments include:

Zero Tolerance to Narcotics

Zero Tolerance for work force violence

Zero tolerance to product quality by design



CHAPTER 3. DESCRIPTION OF ENVIRONMENT

3.1 Background and Salient Environmental Features of the Study Area

Generation of environmental baseline of a project area is an important phase of any Environmental

Assessment process. Baseline data provide vital information on the existing environmental quality in

which an expansion is planned. It is also useful for delineating environmental sensitive areas and for

preparing an Environmental Sensitivity Map for contingency planning. In this study, the environmental

characteristics of the project area (10 km study area) were established through extensive literature

search, field sampling/measurements, laboratory analysis, consultation and data interpretation.

Secondary data from literature search were also obtained from the Govt. sources i.e. Meteorological

Department, CPCB publications; Forest Department and other Govt. Sources. The baseline

environmental data generation has been done for the period of 15th March 2018 to 15

th Jun 2018. M/s JP

Test & Research Centre, Sahibabad, Uttar Pradesh with EQMS Team, carried out sampling and testing.

The study area within a 10 km radius around the proposed plant site has been considered as impact

zone for EIA study. Primary and secondary data has been collected for 10 Km radius of the project site.

3.1.1 Environmental Setting and Salient Environmental Features of the Project Area

The proposed project is an expansion project of existing unit situated at village Fatehgarh

Channa on Mansa road, Tehsil & District Barnala Punjab. As per the EIA notification dated 14th

September 2006, as amended till date, the proposed project falls under category 5(f), Synthetic

Organic chemical and site is not located in notified industrial area, hence proposed expansion

project shall be appraised as Category ―A‖ by MOEF&CC. The proposed project is expanding in

an area of 62 acres with a dense green belt of 30 acres (50% of the total plot area).

The proposed site is at a distance of about 1.45 km,SE from village Fatehgarh Channa. State Highway

13 is at a distance of .81 km NW in Direction. Nearest Railway station is Barnala railway station 8.69 km

from the project site and Chandigarh airport is approx. 130 km away in NE direction from project site

(aerial distance). The rail and road connectivity map of the site is provided in Figure 3.1. Nearest

settlement to the site is Fatehgarh Channa 1.47 km. There is no river present within the study area.

This Chapter describes the baseline environmental conditions around the project site for

various environmental attributes, i.e. physical, biological and socio-economic conditions,

within the 10 km radial zone of the proposed project site, which is termed as the study area.

Topography, drainage, meteorology, air, noise, water, soil and land constitute the physical

environment, where as flora and fauna constitute the biological environment. Demographic

details and occupational pattern in the study area constitute socio-economic environment.



Figure 3.1 Road Connectivity Map

There are no areas protected under international conventions, national or local legislation for their

ecological, landscape, cultural or other related value. There is no national park, wildlife sanctuary,

biosphere reserve and wetland are present within the study area. There is no Reserve and protected

forests are present within 10 km area of the site.

Location map showing site and surrounding environment features within the 10 km area is provided in

Figure 3.3 and Google map of 10 km radius of the site is provided in Figure 3.4. The Salient

Environmental Features of plant site within 500m, 2 Km and 10 Km radius is summarised at Table 3.1.

Table 3.1 : Salient Environmental Features of Proposed Site

S.

No.

Environmental

Features

Within 500 m

area around

project site

Within 2 km

area around

project site

Within 10 km area

around project site

1 Ecological Environment

A Presence of Wildlife

Sanctuary/ National

Park/Biosphere

Reserves

None None None

B Reserved /Protected

Forests

None None None

C Wetland of state and

national interest

None None None

D Migratory route for

wild animals

None None None



E Presence of schedule-

I Fauna

None None None

F Critically polluted Area None within 10 km study area

2. Physical Environment

G Road connectivity None SH-13 SH-13

H Rail connectivity None None Barnala Railway station

I Defence Installation None None None

J Densely Populated

Area

None Fatehgarh

Channa

Fatehgarh Channa

K Other village close to

plant site

None

L Topography 225 m 225 – 231 m 225- 231 m

M Seismicity Seismic zone-III (High damage Risk Zone)

3. Social Environment

Q Physical Setting Industrial Rural and

agricultural

Urban, rural and

agricultural

R Physical Sensitive

Receptors

None School,

Hospitals,

Temple etc.

School, Hospitals,

Temple etc.

S Archaeological

Monuments

None None None



Figure 3.2 Location Map of Study area



Figure 3.3 Google Map of 10 km Study area



3.1.2 Primary Data Collection: Monitoring Plan and Quality Assurance Procedures

Primary baseline data has been collected as per the TOR prescribed by MOEF during 15th March 2018 to

15th June 2018 for one complete season. The study period and methodology for primary data collection is

summarized in Table 3.2.

Table 3.2 : Summary of Methodology for Primary/Secondary Baseline Data Collection

Parameters No. Of

sampling locations

Frequency/ season

Remark

Ambient Air Quality

PM10, PM2.5, SO2 Nox NH3, , CO, HCl

8 locations (Refer Fig.

No.3.5 )

Twice a Week

For Pre-Monsoon season

AAQ monitoring was carried out at 8 locations (representing upwind, downwind and sensitive locations). 24 hours sampling at each location was carried out as per CPCB guide lines (CPCB Gazette notification dated 18.11.2009 on AAQ).

Meteorology

Temperature, Humidity, Wind speed, Direction, Rainfall etc.

One location

Hourly for Pre-

Monsoon season

Met station was established close to the site to record the site-specific hourly met data.

Ground Water Quality

Physical, chemical and biological parameters as per IS

10,500:2012

8 locations

in study area

(Fig 3.5)

Once in a season

Ground water: Sampling was conducted at 8 locations. Samples were preserved, transported and analyzed for different parameters based on APHA methods. Temp, conductivity and pH which were measured instantly at site itself.

Surface Water Quality

Physical, chemical and

biological parameters as per IS: 2296

two locations in study area (Fig 3.6)

Once in a season

Surface Water: Sampling was conducted at two locations. Samples were preserved and transported for analysis for different parameters based on APHA methods. Temp, conductivity, DO and pH which were measured instantly at site itself.

Soil

Texture, bulk density, pH, conductivity, cation exchange capacity, organic matter, Total N,P,K, and Heavy metals etc

6 locations in study area (Fig 3.5)

Once in a season

Soil samples were collected at six locations within the study area and analyzed as per IARI method

Noise



Parameters No. Of

sampling locations

Frequency/ season

Remark

Noise profiling for 24 hrs 8 locations in

study area (Fig 3.6)

Once in season

Noise monitoring was conducted within the 10 km area of project site for noise profiling for 24 hrs using integrated sound level meter, as per CPCB guidelines.

Ecology (Flora & Fauna)

Flora & Fauna

Once Primary survey and Secondary

sources

Demography & Socio-economics

Demography & Socioeconomic - Once Primary survey/ Secondary sources

Standard methods and procedures have been strictly adhered to in the course of this study. QA/QC

procedures were strictly followed which covers all aspects of the study, and includes sample collection,

handling, laboratory analyses, data coding, statistical analyses, presentation and communication of

results. All analysis was carried out in MoEF accredited/recognized laboratory. Environment sampling

Map is provided in Figure 3.5.



Figure 3.4 Environment Sampling Location Map



3.2 Physical Environment

3.2.1 Topography

The topography of proposed site is almost plain. The site elevation ranges between 225 to 231

amsl. Topography around 10 km area of the proposed site is also flat.

3.2.2 Drainage

According to the Watershed Atlas of India, the study area forms part of Lower Sutlej Sub-Basin

below Bhakra Dam. There is no well-defined material drainage system in the area. Two main

drains pass through the area – Upper Lisarna Nala in the northwest and Dhanaula Drain in the

central part. Large network of canals belonging to Bhakra main canal runs through core and

buffer zones

3.2.3 Geology & Hydrogeology

The entire study area is in the Malwa region of this fertile plain. The average elevation of the

district is 227 m, while the soil is little arid towards the southwest and a range of undulating hills run

along its north eastern border, the major part of the province lies in the Northern Indian Fertile

Plains. There is no major river in Barnala. However, the district is watered by two major canal

systems – the Kotla Canal and the Bathinda Branch. Both these canals are branches of Sirhind

canal. The geographical position of the district is plain without hill or stream. Its land can be divided

into two natural tracts, Pouradh and Jangal.

(http://www.barnalaonline.in/city-guide/geography-of-barnala)

3.2.4 Ground water Resources

The elevation of the water table in the district varies from 230 m to 300 m above mean sea

level. The highest elevation is in the northeastern part and the lowest in the southwestern part

and reflects the topographic gradients. The hydraulic gradient in the northern eastern part is

steep, whereas, in the southwestern part, it is gentle. The overall flow of ground water is from

northeast to south-west direction

3.2.5 Depth to Ground Water Table

The depth to water level ranges from 14.43 to 20.62 m bgl during pre-monsoon period and

16.99 to 24.28 m bgl during post monsoon period. The seasonal fluctuation varies from 0.03 to

(-) 3.66 m in the area. The long-term water levels trend indicates average fall of 0.50 m/year.

The long-term water level trend is also showing decline of water level from 8 to 10 m.



Figure 3.5 Depth to water level (Pre Monsoon season)

Figure 3.6 Depth to water level (Post Monsoon Season)



3.2.6 Seismicity of the Study Area

Based on tectonic features and records of past earthquakes, a seismic zoning map of Punjab

State has been prepared by a committee of experts under the auspices of Bureau of Indian

Standard (BIS Code: IS: 1893: Part I 2002. According to the seismic-zoning map of India, the

project area falls in seismic zone-III (Moderate damage Zone). Thus lies among the high-risk

earthquake areas. Seismicity map of study area shown in Figure 3.9.

Figure 3.7 Seismic Zones Map

3.3 Land use

Land use analysis was carried out using remote Sensing Data. Interpretation approach based on

systematic digital imaging was used for delineating the land use classes. The demarcation of boundaries

falling under different land use/land cover units is done using different colours assigned to different land

use/land cover units of satellite imagery. Most of the land within the 10 km area of the project site is

agricultural land. As per the land use based on satellite image, about 88% of the land is Agricultural land,

settlement is about 11% vegetation is about 1%.(Refer Figure 3.9 and Table 3.3).



Table 3.3 : Land use of the Study Area

Class Area(SQ KM) Percentage

Agricultural Land 298.99 87.8349

Waterbody 1.44 0.423032

Settlement 36.46 10.71093

Vegetation 3 0.881316

Barren Land 0.51 0.149824

Total 340.4 100 Source: Satellite Image analysis

Figure 3.8 Area statistics for Land Use / Land Cover Categories in the Study Area



Source: Interpretation of Satellite image

Figure 3.9 Land Use Map of the Study Area (10 km Radial Zone)



3.4 Meteorology

Historical meteorological data was obtained from nearest IMD station located at Ludiana. The

predominant wind direction is from west and northwest direction during winter season. Details

provided in Table 3.4.

Table 3.4 Long Term Meteorological Data of Ludiana (30 years average)

Month

Temperature

(oC) daily

Relative

Humidity (%) Rainfall

(mm)

Predominant Wind Direction

(From)

Wind

Speed

Km/hr Max Min Max Min

January 18.6 5.2 91 63 23.2 NW, W 4.8

February 20.9 6.9 87 59 29.7 NW, W 5.8

March 25.6 11.4 79 54 32.0 NW, W 6.5

April 33.7 16.9 55 32 28.3 NW 6.7

May 38.4 21.9 45 26 27.3 NW 7.1

June 39.2 25.6 54 35 56.1 NW 8.8

July 34.2 25.6 79 64 235.5 SE, NW 7.1

August 33.6 25.2 82 69 195.4 SE, NW 5.5

September 33.7 22.5 78 59 109.1 SE, NW 4.5

October 31.8 16.3 73 47 6.0 NW, W 3.6

November 26.6 10.9 81 53 11.1 NW, W 3.4

December 21.0 6.5 89 61 21.5 NW, W 3.9

Annual Total or

Mean 29.8 16.2 74 52 775.2 NW 5.6

Source: IMD

Temperature– December, January and February constitute winter months with daily mean

minimum temperature around 6.40C and daily mean maximum temperature around 28.9 0C. May

and June is the hottest month with daily mean maximum temperature at 39.2 0C and daily mean

minimum temperature at 23.7 0C.

Relative Humidity–April, May and June are driest with average relative humidity ranges

between 43-60%. The maximum humidity during monsoon season is 84%.

Rainfall– The annual total rainfall is 893 mm. Over 76% of the total annual rainfall is received

during the monsoon period between July to September.



Cloud Cover – In the study area, clear weather prevails in most of the time during post

monsoon, winter and summer seasons. Only during monsoon months of July, August and

September, moderate to heavy clouds are observed.

Wind Speed– The mean wind speed ranges from 4.4 to 5.0 kmph during post-monsoon, 6.6 to

9.3 kmph during monsoon and 7.9 to 8.2 kmph in pre-monsoon season.

Wind Direction– The predominant wind direction is from west and northwest direction in most of

the year except monsoon season where wind blows from east and west direction.

3.4.1 Met Data Generated at Site

Met data for 15th March 2018 to 15th June 2018 was generated at site. An automatic weather

monitoring station was installed at near Project site, keeping the sensors free exposed to the

atmosphere and with minimum interference with the nearby structures. The micro-meteorological

data like wind speed, wind direction, temperature, relative humidity and atmospheric pressure

were collected using the weather stationed cloud cover was recorded manually for the study

period.

The wind directions, wind speed, temperature, rainfall and humidity recorded at site during study

period are presented in Table 3.6. Site specific wind rose diagram for study period is presented

in Figure 3.11.

Table 3.5 Site Specific Meteorological Data

Month Temperature

(deg C)

Relative

Humidity, %

Wind speed

(m/s)

Predominant wind Direction

Calm Period

Min Max Min Max Average (from ) %

March.- 2018 14 30 15 90

25.9 NW 26.19 April.- 2018 17 40 12 89

May.- 2018 20 41 10 90

(Source: Field Survey)



Figure 3.10 Wind Rose Diagram of Study Area (Pre Monsoon Season)

Figure 3.11 Wind Class Frequency Distribution



3.5. Air Environment

Land use of the study area is majorly agricultural with some industrial activities. Source of air

pollution in the study area is majorly vehicular movement, the construction and industrial

activities. Project activities like transportation of raw material and finished material, process

activities and excavation during construction phase may affect the air environment of the project

area.

3.5.1. Selection of Monitoring Stations

To establish the baseline air quality of study area, air quality monitoring study is conducted at 8

locations in project area. AAQ monitoring station was selected considering dominant wind

direction, populated area and sensitive receptors. CPCB guidelines were applied for selecting the

appropriateness of monitoring locations. The location and height of the stations were so selected

(>5 m from base) to avoid the capture of re-suspended road dust and fugitive domestic emissions

due to burning. All the ambient air analysis with respect to each parameter were analysed as per

CPCB guidelines. Details of monitoring locations are shown in Table 3.1. Monitoring Location

map is shown in Figure 3.4. The summary of Ambient Air quality results is presented in Table 3.2.

Table 3.6 : Ambient Air Quality Monitoring Locations

Location Code

Name of Location

Terrain feature Distance/Direction Coordinates

AAQ-1 Project Site Flat terrain,

Industrial 00 30°17'54.73"N

75°30'3.23"E

AAQ-2 Fatehgarh Chhanna

Flat terrain, 1.68km,SE 30°16'55.78"N 75°30'53.72"E

AAQ-3 Kaleke Flat terrain 7.12km,SE 30°14'22.06"N

75°32'30.51"E

AAQ-4 Dhanaula

Flat terrain 7.56km,SE 30°17'1.59"N 75°34'27.44"E

AAQ-5 Dhaula

Flat terrain 3.84km,SW 30°17'12.77"N 75°27'35.12"E

AAQ-6 Ghunas

Flat terrain 7.88km,NW 30°18'42.65"N 75°25'19.09"E

AAQ-7 Handiaya

Flat terrain 4.90km,N 30°20'9.26"N 75°30'34.46"E

AAQ-8 Barnala Flat terrain 8.87km,NE 30°22'14.11"N

75°32'46.49"E

3.5.2. Analysis of Ambient Air Quality of the Project Area

Ambient air quality results for all the eight locations are presented in Table 3.2.



Table 3.7 : Ambient Air Quality Monitoring Results for PM2.5 and PM10(24-hour average)

Location PM2.5 (µg/m³) PM10 (µg/m³)

Min Max Mean 98 Percentile Min Max Mean 98 Percentile

Project Site 38 56 45 54 74 97 88 97

Fatehgarh Chhanna 40 62 48 60 77 112 92 111

Kaleke 33 66 47 63 68 110 89 109

Dhanaula 31 69 44 63 58 107 85 106

Dhaula 35 62 44 60 69 112 87 110

Ghunas 32 57 42 54 67 104 85 103

Handiaya 33 59 47 57 70 109 90 106

Barnala 37 57 48 56 76 115 93 114

Table 3.7 Conti... Ambient Air Quality Monitoring Results for SOx and NOx (24-hrs avg.)

Location SO₂ (µg/m³) NO₂ (µg/m³)


Project Site 7.2 19.8 12.7 18.6 14.2 41.2 26.4 38.6

Fatehgarh Chhanna 6.8 17.5 11.8 16.1 14.0 39.3 22.7 37.4

Kaleke 6.2 16.3 10.9 16.0 15.8 35.0 23.2 33.4

Dhanaula 6.5 17.0 11.4 16.4 15.3 32.2 21.1 30.7

Dhaula 7.0 18.8 12.5 18.1 16.5 35.5 23.8 34.0

Ghunas 6.6 16.0 11.0 15.4 14.3 30.2 21.6 29.7

Handiaya 7.4 20.5 12.7 19.3 16.5 31.1 23.0 30.7

Barnala 6.9 18.4 12.2 18.4 19.3 36.9 27.4 36.0

Table 3.7 Conti... Ambient Air Quality Monitoring Results for SOx and NOx (24-hrs avg.)

Location NH3 (µg/m³) CO (mg/m³)


Project Site 11 20 15 20 0.28 0.46 0.36 0.45

Fatehgarh Chhanna 9 15 12 15 0.37 0.81 0.64 0.80

Kaleke 10 16 12 16 0.22 0.56 0.33 0.49

Dhanaula 12 17 14 17 0.28 0.53 0.38 0.51

Dhaula 10 16 13 16 0.14 0.28 0.19 0.27

Ghunas 10 15 12 15 0.23 0.42 0.33 0.42

Handiaya 9 15 11 15 0.15 0.32 0.25 0.32

Barnala 13 23 17 22 0.43 0.76 0.64 0.76



Table 1.2 Conti...

Location Code Location VOC (µg/m³) HCL (µg/m³)

AAQ-1 Project Site <0.1 <0.1 AAQ-2 Fatehgarh Chhanna <0.1 <0.1 AAQ-3 Kaleke <0.1 <0.1 AAQ-4 Dhanaula <0.1 <0.1 AAQ-5 Dhaula <0.1 <0.1 AAQ-6 Ghunas <0.1 <0.1 AAQ-7 Handiaya <0.1 <0.1 AAQ-8 Barnala <0.1 <0.1

3.5.3. Observation on Ambient Air Quality

Particulate Matter (PM10): Particulate Matter PM10 levels were found ranging from 67 to 115

µg/m3. The mean concentration of PM10 in all location ranges between 85 to 93 µg/m

3. The

maximum PM10 levels in all location are exceeding the specified limits (100 g/m3) as per NAAQS

except plant site. However the mean concentrations of PM10 levels are well within specified limits

(100 g/m3) as per NAAQS. This may be due to the dust generated from thrashing of Wheat crop

in the agricultural field, presence of industries in addition to plying of heavy traffic such as trucks

and other combustion engine vehicles in nearby roads.

Particulate Matter (PM2.5): PM2.5 levels were found ranging from 31 to 69 µg/m3. The mean

concentration of PM2.5 in all location ranges between 42 to 48 µg/m3. The maximum PM2.5 levels

in all location are exceeding the specified limits (60 g/m3) as per NAAQS except project site ,

Ghunas, Handiaya and Barnala. While the mean concentration of PM2.5 levels is well within the

specified limit of 60 g/m3. This may be due to the dust generated from thrashing of Wheat crop in

the agricultural field, presence of industries in addition to plying of heavy traffic such as trucks and

other combustion engine vehicles in nearby roads.

Sulphur Dioxide (SO2): The SO2 level in all the location ranges between 6.2-20.5 µg/m3, which

was found well within National Ambient Air Quality standards i.e. NAAQMS ( 80µg/m3). The

highest SO2 level were found at Handiaya (20.5 µg/m3) and lowest SO2 level were observed also

at Kaleke (6.2 µg/m3).

Oxides of Nitrogen (NOx): The NOx level in all the location ranges between 14.0-41.2 µg/m3,

which was found well within National Ambient Air Quality standards i.e. NAAQMS (80µg/m3). The

highest NOx level were found at Project site (41.2 µg/m3) and lowest NOx level were observed

also at Fatehgarh Channa (14.0 µg/m3).

Ammonia (NH3): The NH3 level in all monitoring locations ranges between 9 to 23 µg/m3. The

NH3 level in all monitoring location is under permissible limit i.e. NAAQMS 400 µg /m³.

Carboon Monoxide (CO): The 8 hrs. CO level in all monitoring locations ranges between 0.14 to

0.81 mg/m³. The CO level in all monitoring location are under permissible limit i.e. NAAQMS level

2 mg/m³.

Other Parmeters: VOC, HBr and HCL were not detected in the study area.



Overall the mean PM level in the study area are within the prescribed National Ambient Air

Quality Standard, 2009 (CPCB) at all locations.

3.5.4. Comparison of Ambient Air Quality Data with Available Secondary Data

Secondary air quality data for project area is referred from SPCB, Punjab is given in Table 3.8.

SPCB has established an on-line monitoring station at vill, Aspal Khurad (Kahneke), Tehsil-Tapa,

Distt-Barnal which is located about 10 km from the proposed site. The Month wise AAQ results

are given below:

Table 3.8 Month wise AAQ Data (Jan to May 2018)

Month Location RSPM (μg/m3 NO2 (μg/m3) SO2 (μg/m3) 3

January

vill, Aspal Khurad (Kahneke)

119 13 4.0

February 94 11 4.0

March 87 10 4.0

April 129 14 5.0

May 108 18 5.0

Average 107.4 13.2 4.4

Source: SPCB, Punjab Online Monitoring Station

3.6. Noise Environment

Noise after a certain level can have a very disturbing effect on the people and animals exposed

to it. Hence, it is important to assess the present noise quality of the area in order to predict the

potential impact of future noise levels due to the proposed project. Ambient noise

measurements were taken at 8 locations, represented in Table 3.9. Location wise result for day

time and night time is presented in Table 3.10.

The monitored levels were compared against the Noise Pollution (Regulation and Control) Rules

2000, as amended through the Noise Pollution (Regulation and Control) Amendment Rules

2010 dated 11th January 2010. The project site falls in designated industrial area and the noise

levels at all the locations were found within the ambient noise standards.

Table 3.9 Ambient Noise Quality Monitoring Locations

S. No. Measurement Location Distance/Direction Coordinates

N-1 Project Site

00 30°17'54.73"N 75°30'3.23"E

N-2 Handiaya Chowk NH-64

1.68km,SE 30°16'55.78"N 75°30'53.72"E

N-3 Near NH-71

5.91 km,SE 30°18'44.42"N 75°33'48.50"E

N-4 Dhaula SH-13

7.56km,SE 30°17'1.59"N 75°34'27.44"E



N-5

Khudi Khurd

5.21 km,NW 30°19'35.16"N

75°27'14.14"E

N-6 Fatehgarh Chhanna

7.88km,NW 30°18'42.65"N 75°25'19.09"E

N-7 Chhanna

4.90km,N 30°20'9.26"N 75°30'34.46"E

N-8 Trident site

8.87km,NE 30°22'14.11"N 75°32'46.49"E

Table 3.10 Ambient Noise Quality in the Study Area

Source: Primery Data Collection and analysis

3.4.2 Observation on Ambient Noise Quality:

The sources of noise in the villages of study area are motorcycle and car/jeep, bus and truck

movement. The ambient noise level of all the monitoring locations were found well within the

National Ambient Noise Quality Standards prescribed for industrial (Standards - 75 dBA during

day time and 70 dBA during night time) residential area (Standards - 55 dBA during day time and

Location

Code

Name of Measurement

Location

Day

Time

Leq

dB(A)

National

Standard

Day Time

Leq dB(A)

Night

Time Leq

dB(A)

National

Standard

Night Time

Leq dB(A)

N-1 Project Site 56.7 75.0 42.4 70.0

N-2 Handiaya Chowk NH-64 52.2 55.0 41.2 45.0

N-3 Dhanaula NH-71 63.8 65.0 58.3 55.0

N-4 Dhaula SH-13 53.6 55.0 42.2 45.0

N-5 Khudi Khurd 60.8 65.0 54.6 55.0

N-6 Fatehgarh Chhanna 51.2 55.0 41.4 45.0

N-7 Chhanna 58.9 65.0 53.8 55.0

N-8 Trident site 50.5 55.0 41.0 45.0



45 dBA during night time) and commercial area (Standards - 65 dBA during day time and 55

dBA during night time). The Ambient noise are well within the limit as per prescribe standard.

3.7. Traffic Study

The site is in planned industrial area of trident group having a good network of internal roads.

Further the site is located close to State Highway-13 which is passing about 800 m of the project

site.

As the site is located close to SH-13 and all the material movement shall be done through this

highway. The SH - 13 is two lanes (2-lane) of very good design (1.5 m hard shoulders and 3 m

central verge) and its capacity is 40000 PCU per day as per IRC specification (IRC64-1990).

Considering total material transport from IOLCP i.e. 10-15 truck/month, the existing highway is

adequate to bear the additional load without any issue.

3.8. Water Quality

3.8.1. Ground Water Quality

Eight ground water samples were collected from different locations around the site during study

period. The water samples were examined for physico-chemical parameters and bacteriological

parameters. The samples were collected and analysed as per the procedures specified in

Standard Methods. Samples for chemical analyses were collected in polyethylene carboys.

Samples for bacteriological analyses were collected in sterilized bottles. Temperature, pH,

conductivity and dissolved oxygen were measured at site itself. The name of ground water

sampling locations is presented in Table 3.11. The analysis results of groundwater are

presented in Table 3.12.

Table 3.11 Ground Water Sampling Locations

Code Stations Source Dist./Dir Coordinates

Ground water

GW1 Project Site Borewell Water Site

GW2 FatehgarhChhanna Borewell Water 2km,SE 30°16'52.69"N 75°31'19.71"E

GW3 Chhanna Hand Pump 0.95km,W 30°17'50.98"N 75°29'24.48"E

GW4 Khudi Khurd Well Water 4.78,NW 30°19'40.95"N 75°27'35.27"E

GW5 KahneKe Hand Pump 6.88km,SE 30°14'38.29"N 75°32'43.31"E

GW6 Fatehpur Pindi Hand Pump 6.45km,SW 30°16'52.13"N 75°26'12.29"E

GW7 Handiaya Well Water 2.64km,N 30°19'39.80"N 75°29'54.00"E

GW8 Dhoorkot Hand Pump 6.52km,SW 30°14'39.85"N 75°27'26.94"E



Table 3.12 Ground Water Quality in the Study Area

S.N. Parameters GW1

GW2

GW3

GW4

Method Desired Limit

/Permissible Limit

1 pH Value 8.18 7.70 7.68 7.49 APHA-4500 6.5-8.5/

No relaxation

2 Temperature 0C 24.8 25.6 25.0 25.5 Part 9 --

3 Conductivity, mhos/cm 838 1120 1072 960 APHA-4500 --

4 Turbidity (NTU) <1 <1 <1 <1 APHA-2030B 1-5

5 Total Dissolved Solids mg/l 545 728 698 625 APHA-2540B 500/2000

6 Total Suspended Solids mg/l <2 <2 <2 <2 APHA-2540D --

7 Total Hardness as CaCO3 mg/l

204 356 245 236 APHA-2340C 200/600

8 Chloride as Cl mg/l 72 93 114 138 APHA-4500B 250/1000

9 Total Alkalinity mg/l 288 412 392 290 Part -23 200/600

10 Sulphates as SO4 mg/l 102 138 87 88 APHA-4500E 200/400

11 Nitrates as NO3 mg/l 28 34 42 18 APHA-4500 45/No relaxation

12 Fluoride as F mg/l 0.52 0.92 0.86 0.66 APHA-4500D 1/1.5

13 Iron as Fe mg/l 0.28 0.24 0.29 0.27 APHA-3111B 0.3/No relaxation

14 Zinc as Zn mg/l 0.98 1.34 1.12 0.88 APHA-3111B 5/15

15 Calcium as Ca mg/l 52 104 62 72.8 APHA-3500B 75/200

16 Magnesium as Mg mg/l 18 23.8 22 13.1 APHA-3500B 30/100

17 Sodium as Na mg/l 68 58 96 84 APHA-3500 --

18 Potassium as K mg/l 29 27 35 33 APHA-3500 KB --



19 Cadmium as Cd mg/l <0.01 <0.01 <0.01 <0.01 APHA-3111B 0.003/No relaxation

20 Copper as Cu mg/l <0.01 <0.01 <0.01 <0.01 APHA-3111B 0.05/1.5

21 Nickel as Ni mg/l <0.01 <0.01 <0.01 <0.01 APHA-3111B 0.02/No relaxation

22 Lead as Pb mg/l <0.01 <0.01 <0.01 <0.01 APHA-3111B 0.01/No relaxation

23 Mercury as Hg mg/l <0.001 <0.001 <0.001 <0.001 APHA-3112 0.001/0.001

24 Chromium (Total as Cr) mg/l <0.05 <0.05 <0.05 <0.05 APHA-3111B 0.5/No relaxation

25 Arsenic as As mg/l <0.01 <0.01 <0.025 <0.025 APHA-3114 0.01/0.05

26 Phenolic compound mg/l <0.001 <0.001 <0.001 <0.001 Part 43 0.001/0.002

27 Total Coliform MPN/100ml Nil Nil Nil Nil APHA-9230B Nil

Source: Primary Data Collection and analysis during study period by Laboratory

Table 3.15 Continued..........Ground Water Quality in the Study Area

S.N. Parameters GW5 GW6 GW7 GW8 Method Desired Limit

/Permissible Limit

1 pH Value 7.59 7.05 7.42 7.32 APHA-4500 6.5-8.5/No relaxation

2 Temperature 0C 25.2 25.3 25.0 25.7 Part 9 --

3 Conductivity, mhos/cm 856 550 879 1060 APHA-4500 --

4 Turbidity (NTU) <1 <1 <1 <1 APHA-2030B 1-5

5 Total Dissolved solids mg/l 557 358 572 689 APHA-2540B 500/2000

6 Total Suspended solids mg/l <2 <2 <2 <2 APHA-2540D --

7 Total Hardness as CaCO3 mg/l 285 182 310 288 APHA-2340C 200/600

8 Chloride as Cl mg/l 122 56 68 132 APHA-4500B 250/1000

9 Total Alkalinity mg/l 312 204 310 412 Part -23 200/600



10 Sulphates as SO4 mg/l 52.8 42 26.2 76.8 APHA-4500E 200/400

11 Nitrates as NO3 mg/l 28 23 18 8.9 APHA-4500 45/No relaxation

12 Fluoride as F mg/l 0.67 0.56 0.87 0.88 APHA-4500D 1/1.5

13 Iron as Fe mg/l 0.29 0.22 0.27 0.22 APHA-3111B 0.3/No relaxation

14 Zinc as Zn mg/l 1.52 0.82 1.10 0.96 APHA-3111B 5/15

15 Calcium as Ca mg/l 78 70 98 86 APHA-3500B 75/200

16 Magnesium as Mg mg/l 22 1.9 16 17.8 APHA-3500B 30/100

17 Sodium as Na mg/l 57 29 36 86 APHA-3500 --

18 Potassium as K mg/l 6.8 2.1 7 17 APHA-3500 KB --

19 Cadmium as Cd mg/l <0.01 <0.01 <0.01 <0.01 APHA-3111B 0.003/No relaxation

20 Copper as Cu mg/l <0.01 <0.01 <0.01 <0.01 APHA-3111B 0.05/1.5

21 Nickel as Ni mg/l <0.01 <0.01 <0.01 <0.01 APHA-3111B 0.02/No relaxation

22 Lead as Pb mg/l <0.01 <0.01 <0.01 <0.01 APHA-3111B 0.01/No relaxation

23 Mercury as Hg mg/l <0.001 <0.001 <0.001 <0.001 APHA-3112 0.001/0.001

24 Chromium (Total as Cr) mg/l <0.05 <0.05 <0.05 <0.05 APHA-3111B 0.5/No relaxation

25 Arsenic as As mg/l <0.025 <0.025 <0.01 <0.01 APHA-3114 0.01/0.05

26 Phenolic compound mg/l <0.001 <0.001 <0.001 <0.001 Part 43 0.001/0.002

27 Total Coliform MPN/100ml Nil Nil Nil Nil APHA-9230B Nil




Observation on Water Quality Ground water

The pH value of drinking water is an important index of acidity or alkalinity. pH

value was found within desired and permissible limit, neutral to alkaline in nature.

Total dissolve solids was found in the range of 358 to 728 mg/l which found

slightly above the desired limit but well within permissible range of IS 10500:2012.

Chloride was found in the range of 56 to 138 mg/l which found well within desired

range (250 mg/l) of IS 10500:2012

Total hardness values ranges between 182 to 356 mg/l which is higher than the

desired limit at in few locations but within the permissible limits.

Ca values and sodium values are also found in higher side. Fluoride contents in

traces were also found in the ground water sample but it was well within the

permissible limits.

Overall the ground water quality of the study area is found well within the

permissible limits. No metallic and bacterial contaminations were observed in

ground water samples.

.

3.8.2. Surface Water Quality

There is no perennial river within the study area. Irrigation canal (Uppli Canal) and ponds are

the source of surface water. There is a waste water drain flowing close to the site. it is

contaminated due to direct discharge of waste water from industries. Six surface water

samples were collected and examined for major physico-chemical parameters and

bacteriological parameters. CPCB best designated Use standards are shown in Table 3.13.

Surface water sampling locations are presented in Table 3.14. Surface water results

provided in Table 3.15.

Table 3.13 CPCB Best Designated Use Standard (Source-CPCB)

Designed Best Use Class of Water Criteria

Drinking water Source without conventional treatment but after disinfection

A Total Coliforms Organism MPN/100ml shall be 50 or less pH between 6.5 and 8.5 Dissolved Oxygen 6mg/l or more Biochemical Oxygen Demand 5 days 20°C 2mg/l or less

Outdoor bathing (Organized)

B Total Coliforms Organism MPN/100ml shall be 500 or less



pH between 6.5 and 8.5 Dissolved Oxygen 5mg/l or more Biochemical Oxygen Demand 5 days 20°C 3mg/l or less

Drinking water source after conventional treatment and disinfection

C Total Coliforms Organism MPN/100ml shall be 5000 or less pH between 6 to 9 Dissolved Oxygen 4mg/l or more Biochemical Oxygen Demand 5 days 20°C, 3mg/l or less

Propagation of Wild life and Fisheries

D pH between 6.5 to 8.5 Dissolved Oxygen 4mg/l or more Free Ammonia (as N) 1.2 mg/l or less

Irrigation, Industrial Cooling, Controlled Waste disposal

E pH between 6.0 to 8.5 Electrical Conductivity at 25°C micro mhos/cm Max.2250 Sodium absorption Ratio Max. 26 and Boron Max. 2mg/l

Table 3.14 Sampling Location Surface Water

Code Stations Distance/Direction Coordinates

SW 1 Nala 100 Meter Upstream

at Project Site

0.30km,NW 30°18'3.61"N

75°29'47.43"E

SW 2 Nala 100 Meter

Downstream at Project Site

0.35km,E 30°17'51.33"N

75°30'36.69"E

SW 3 Canal 100 Meter Upstream

at Near Dhaula

3.87km,SW 30°17'3.89"N

75°27'39.81"E

SW 4 Canal 100 Meter

Downstream at Near

Dhaula

3.46km,SW 30°16'53.46"N

75°28'2.12"E

SW 5 Dhaula Pond 3.82km,SW 30°17'2.24"N

75°27'49.32"E

SW 6 KahneKe Pond 7.15km,SE 30°14'25.25"N

75°32'21.78"E



Table 3.15 Surface Water Quality in the Study Area

S.N. Parameters SW1

SW2

SW3

SW4

SW5

SW7

Method

1 pH Value 8.04 8.10 7.76 7.80 7.92 7.99 APHA-4500

2 Temperature 0C 25.8 25.5 25.2 25.5 25.8 2.6 Part 9

3 Conductivity, mhos/cm 964 972 334 340 388 396 APHA-4500

4 Turbidity (NTU) 12 14 <5 <5 <5 <5 APHA-2030B

5 Total Dissolved solids mg/l 626 630 216 221 252 257 APHA-2540B

6 Total Suspended solids mg/l 48 54 3 5 7 9 APHA-2540D

7 Total Hardness as CaCO3 mg/l 398 408 138 142 162 166 APHA-2340C

8 Chloride as Cl mg/l 82 86 26 28 34 36 APHA-4500B

9 Total Alkalinity mg/l 342 346 118 122 138 140 Part -23

10 Sulphates as SO4 mg/l 39.8 42.2 16.8 18.0 19.2 21.6 APHA-4500E

11 Fluoride as F mg/l 0.98 1.02 0.28 0..30 0.52 0.56 APHA-4500D

12 Iron as Fe mg/l 0.52 0.60 0.20 0.23 0.34 0.35 APHA-3111B

13 Zinc as Zn mg/l 1.98 2.12 0.16 0.19 0.64 0.68 APHA-3111B

14 Calcium as Ca mg/l 142.4 147.2 48 50.4 60 60.8 APHA-3500B

15 Magnesium as Mg mg/l 10.2 7.3 4.4 3.9 2.9 2.4 APHA-3500B

16 Cadmium as Cd mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 APHA-3111B

17 Copper as Cu mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 APHA-3111B

18 Nickel as Ni mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 APHA-3111B

19 Lead as Pb mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 APHA-3111B



20 Mercury as Hg mg/l <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 APHA-3112

21 Chromium (Total as Cr) mg/l <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 APHA-3111B

22 Arsenic as As mg/l <0.025 <0.025 <0.025 <0.025 <0.025 <0.025 APHA-3114

23 Oil & Grease mg/l 3.6 3.9 ND ND 1.2 1.0 Part -39

24 Chemical Oxygen Demand as COD mg/l 92 98 08 09 18 20 Part -58

25 Bio- Chemical Oxygen Demand as BOD (for

3 Days 27 ˚C) mg/l

16 29 2.6 2.7 5.2 5.4 Part -44

26 Dissolved Oxygen mg/l 3.9 3.8 6.8 6.6 6.2 6.0 APHA

27 Total Coliform MPN/100ml 4560 6420 310 315 1880 1920 APHA-9230B



EQMS India Pvt. Ltd. Page 168

Observation on Surface water Quality:



upstream and downstream point of the project site high bacterial contamination were observed in

Nala water quality meeting the BDU criteria Class D which is fit for propagation of wildlife and

fisheries.

Canal Water quality: The canal water quality is good for Drinking water source after conventional

treatment and disinfection and meeting the class C of Best designated uses of CPCB.

Pond Water Quality: Bacterial contamination were observed in pond water samples. Dissolve

oxygen is found within the range while BOD was found slightly on slightly high than the Class C of

Best designated uses. Hence the pond water is fit for Propagation of Wild life and Fisheries and

meeting the criteria D of Best designated uses of CPCB.

3.9. Soil Quality

Soils may be defined as a thin layer of earth's crust that serves as a natural medium for the growth

of plants. It is the unconsolidated mineral matter that has been subjected to and influenced by

genetic and environmental factors. Soils serve as a reservoir of nutrients for plants and crops and

also provide mechanical anchorage and favorable tilts. Soil is our most important natural resource

and a natural resource is anything that comes from the earth and is used by us. We depend on the

soil for food, clothing, shelter, minerals, clay & water. Soil is the seat of many macro & micro flora

like algae, fungi, earthworms, bacteria etc. These are very beneficial in promoting soil reactions

and decomposing the organic matter by which essential nutrients for plants are liberated. Most of

the soils are made-up of two main parts:

Tiny bits of mineral particles which come from larger rocks, and humus, which is dark brown in color and consists of decaying remains of plants and animals.

Soil also contains water, air and living organisms, such as fungi, bacteria, earthworms, roundworms, insects, etc. Actually, more living organisms live in the soil than above it.

For general characterization of soil a few random samples from the study area to the depth of

about 15-cm may be sufficient. Deeper soil samples may be needed only for the study of soil

profile.

3.8.1. Methodology

The soil samples were collected from Six (06) selected locations during the Pre-monsoon season (15th March-15th June 2018). The samples collected from all the locations were homogeneous representative of each sampling location. At random five sub-locations were identified at each location and soil samples were collected from 5 to15-cm below the surface of soil. It was uniformly mixed before homogenizing the soil sample. The samples about 500-gms were packed in polythene bags labelled in the field with the name of sampling location & number and sent to the laboratory for the analysis of physicochemical parameters. The samples were dried and passed through a 2.0 mm sieve to prepare them for testing.



3.8.2. Soil Sampling Locations

For studying soil quality in the study area, Six (06) sampling locations were selected to assess the

existing soil conditions in and around the existing plant area representing various land use

conditions. Soil sampling locations with their distance & directions w. r. t., the proposed project site

are presented in Table: 3.16.

Table 3.16 : Soil Sampling Locations

Sample Code Sampling Locations Distance,

Directionkm

Coordinates

S-1 Project Site

S-2 Chhanna 1.31km,W 30°17'57.82"N 75°29'13.42"E

S-3 FatehgarhChhanna 1.52km,SE 30°16'59.57"N 75°30'44.16"E

S-4 Dhaula 4.21km,W 30°17'28.75"N 75°27'21.88"E

S-5 Khudi Khurd 5.68km,NW 30°19'43.60"N 75°26'59.12"E

S-6 Dhanaula 2.65km,NE 30°18'13.54"N 75°31'45.27"E

3.8.3. Analysis of Soil Samples

The soil samples were examined for various physicochemical parameters, to determine the

existing soil characteristics of the study area. Soil samples were collected from the vicinity of

proposed project site. Physicochemical characteristics of soil are presented in Table: 3.17 as

follows,

Table 3.17 Physiochemical Characteristics of Soil

S.

No.

Parameters Unit Project

Site

(S-1)

Chhanna

(S-2)

Fatehgarh

Chhanna

(S-3)

Dhaula

(S-4)

Khudi

Khurd

(S-5)

Dhanaula

(S-6)

Physical Characteristics

1. Colour - Light

Brown

Light

Brown

Light

Brown

Light

Brown

Light

Brown

Light Brown

2. Texture USDA Sandy

Loam

Sandy

Loam

Sandy

Loam

Sandy

Loam

Sandy

Loam

Sandy Loam

3. Porosity % 46.4 47.9 50.2 49.1 45.3 46.8

4. Bulk Density gm/cc 1.42 1.38 1.32 1.35 1.45 1.41

5. Water Holding

Capacity

% 29.5 28.6 30.5 29.8 29.4 30.8

6. Particle Size Distribution

i). Sand % 55 58 55 52 56 54

ii). Silt % 32 28 32 29 32 28

iii). Clay % 13 14 13 16 12 18

7. Permeability cm/hr 1.78 1.55 1.78 1.24 2.03 0.96

Chemical Characteristics

8. pH 20% Slurry 7.75 7.58 7.88 7.82 7.85 7.76

9. Conductivity (EC) µmhos/cm 345.2 382.5 358.4 426.5 365.4 375.5

10. CEC meq/100gm 9.8 10.6 10.5 11.8 9.2 11.5

11. Organic Carbon % 0.48 0.46 0.55 0.52 0.51 0.58



12. Organic Matter % 0.83 0.79 0.95 0.90 0.88 0.99

13. Chloride as Cl mg/kg 145.8 244.6 188.6 168.2 158.6 195.2

14. Magnesium as Mg mg/kg 189.4 175.8 188.6 176.4 156.5 172.4

15. Zinc as Zn mg/kg 1.45 1.65 1.72 1.74 1.68 1.82

16. Iron as Fe mg/kg 5.42 4.81 7.24 6.86 5.57 4.62

17. Copper as Cu mg/kg 0.68 0.75 0.64 0.55 0.59 0.48

18. Manganese as Mn mg/kg 4.85 5.64 5.44 4.46 4.75 5.94

19. Boron as B mg/kg 0.75 0.82 0.74 0.71 0.68 0.59

20. Available Nutrients

i). Nitrogen as N kg/ha 288.4 269.6 298.5 285.2 278.5 282.7

ii). Phosphorus as P kg/ha 24.2 25.5 18.5 21.8 22.6 20.5

iii). Potassium as K kg/ha 185.6 156.2 165.5 174.6 176.4 168.7

21. SAR - 1.55 1.45 1.42 1.51 1.48 1.54

2.4 Interpretation of Analytical Results & Conclusion

On the basis of above Soil Testing results in the study area the conclusion may be revealed as

follows;

Physiochemical Characteristics of Soil

Physical Properties

Texturally the soils in the study area are observed as Sandy Loam Soils. The bulk density of the

soils was found in the range of 1.32 to 1.45 gm/cm3. Porosity was observed in the range of 45.3

to 50.2% in the soils of the study area. Water Holding Capacity of study area soils was observed

as 28.6 to 30.8%. The results show the Permeability levels were found to be varied from 0.96 to

2.03 cm/hr under Sandy Loam Soils in the study area.

Chemical Properties

Soil Reaction Classes and Critical Limits for Macro & Micro Nutrients in Soil

According to Soil Survey Manual (IARI, 1970), the soils are grouped under different soil reaction

classes viz; extremely acidic (pH<4.5), very strongly acidic (pH 4.5-5.0), strongly acidic (pH 5.1-

5.5), moderately acidic (pH 5.6-6.0), slightly acidic (pH 6.1-6.5), neutral (pH 6.6-7.3), slightly

alkaline (pH 7.4-7.8), moderately alkaline (pH 7.9-8.4), strongly alkaline (pH 8.5-9.0).The soils are

rated as low (<0.50%), medium (0.50-0.75%) and high (>0.75%) in case of organic carbon, low

(<280kg/ha), medium (280 to 560kg/ha) and high (>560kg/ha) in case of available Nitrogen, low

(<10kg/ha), medium (10 to 25kg/ha) and high (>25kg/ha) for available Phosphorus, low

(<108kg/ha), medium (108 to 280kg/ha) and high (>280kg/ha) for available Potassium & low

(<10mg/kg), medium (10-20mg/kg) and high (>20mg/kg) for available Sulphur (Singh et. al. 2004,

Mehta et. al.1988). Critical limits of Fe, Mn, Zn, Cu and B, which separate deficient from non-

deficient soils followed in India, are, 4.5, 2.0, 0.5, 0.2 & 0.5mg/kg respectively. (Follet & Lindsay

1970 and Berger & Truog 1940)

The soil pH ranges from 7.58 to 7.85, thereby indicating the soils are slightly alkaline in nature.

The organic carbon content of soil varied from 0.46 to 0.58% (0.79 to 0.99% as organic matter),

thereby implying that soils are with low to medium organic content. Available nitrogen content in

the surface soils ranges between 269.6 & 298.5 kg/ha thereby indicates that soils are low in

available nitrogen content. Available phosphorus content ranges between 18.5 & 25.5 kg/ha



thereby is indicating that soils are medium in available phosphorus content. Available potassium

content in these soils ranges between 156.2 & 185.6 kg/ha thereby is indicating that the soils are

medium in potassium content.

The available manganese content in surface soils was recorded as 4.46 to 5.94 mg/kg as the

critical limit of available manganese is 2.0 mg/kg. The available Zinc in surface soils of the study

area ranges from 1.45 to 1.82 mg/kg. As per the critical limit of available Zinc as 0.5 mg/kg, most

of the study area soils are with sufficient available Zinc level in the vicinity of the project. Above

description of study area soils reveals that the soils in the study area are having moderate fertility

index.

3.10. Ecology

The Botanical and wildlife species in an area depend on the availability of suitable habitat for

survival. Habitat loss and increasing habitat fragmentation are the primary causes of species

decline in these environments. This section provides an overview of flora and fauna observed in

study area during site visit.

Forest Cover in Barnala District: As per the India State of Forest Report, ISFR 2017 there is

only 8 sqkm forest in the Barnala district. Most of the land in Barnala district is under agriculture.

The details of the forest type present in the Barnala district is given in Table 3.18.

Table 3.18 Type of Forest in Barnala District

Sl.

No.

Forest Type Area in Sq. KM

1 Very Dense Forest Nil

2 Dense Forest 01

3 Open Forest 07

4 Total geographical area 2414

Source: India State of Forest Report, ISFR 2017

Though there is very little forests observed and the crop comprises of mainly Eucalyptus plantation

which is stagnating and not doing well probably due to Kankar pan in the area or water table which

is lowering gradually. Some trees of Kikar, subabul, Toot, are also found in the area. The area has

been intensively planted with Mulberry and Eucalyptus. Under growth is scanty. It consists of

shrubs like Zizyphus nummular (Mallah), Calotropis procera (Aak). Amongest the grasses

Cynodon dactylon (Khabal) ,Congress grass, Bhang (Cannabis sativa)are very common

.



3.10.1. Flora of Study Area

Proposed expansion to be done within the existing premises. No tree cutting is required. No major

vegetation is present within the core zone hence no wildlife exists within the core zone.

Most of the land around the study area (10 km radius around the project site) is under agriculture

and residential uses. No national parks, wild life sanctuary, biosphere reserve is present within 10

km area of the project site. No Reserve Forest and protected forests are present within the study

area. Because there is no forest in the study area and the vegetation is restricted along road side

and other open areas. The vegetation is meager in spite of the favorable environmental conditions.

At some places, area is covered with thick vegetation. The plants are a significant characteristic

tress comprises of mainly Eucalyptus etc. Some trees of Kikar, subabul, Toot, are also found in

the area. Around village roads, Pipal (Ficus religiosa), Bargad (Ficus benghalensis), Neem

(Azadirachta indica), Babul (Acacia niotica), Dhak (Butea monosperma), Jamun (Syzygium

cumini), Nilgiri (Eucalyptus globulus) and Amaltash (Cassia fistula) were commonly observed.

Among the fruit trees, the important ones were Ziziphus mauritiana (Ber), Syzgium cumini (jamun)

and Psidium guajava (Amrud). Dischanthum annuatum, a fodder grass wa s growing on normal

soils while Cenchrus celaris another fodder species grows on sandy soil patches. Other grasse s

found in the study area are Diplachne fusca, Heteropogon controutus, Sporobolous maraginatus,

Aristida hixtrix, Dactylon centicem, etc. Weeds like Calotropis gigantea, Ricinus communis,

Alternanthera sessilis and Achyranthes aspera were commonly observed on the banks of fields.

The list of the plant species observed in the study area is given Table 3.19

Table 3.19 List of Common Plant Species Present in Study Area

Sr. No. Botanical Name Local Name Family

1. Trees

1. Acacia Arabica Babul Mimosaceae

2. Alstonia scholaris Apocy naceae

3. Aegle marmelos Bel Rutaceae

4. Ailanthus excelsa Mahaneem Simarubaceae

5. Albizza lebbeek Siris Mimosaceae

6. Albizza procera Asfed siris Mimosaceae

7. Azadiracta indica Neem Meliaceae

8. Butea monosperma Palas Fabaceae

9. Bombax ceiba Semal Malvaceae

10. Bauhinia varigata Kachnar Leguminoseae

11. Cassia fistula Amaltas Leguminoseae

http://www.google.co.in/search?hl=en&ei=3YCxS56CO4qwrAfw5tGEBA&sa=X&oi=spell&resnum=0&ct=result&cd=1&ved=0CBIQBSgA&q=Leguminosae&spell=1




12. Dalbergia latifolia Shisham Fabaceae

13. Dalbergia sissoo Sissoo Fabaceae

14. Delonix regia Gulmohar Caesalpiniaceae

15. Emblica officinalis Aonla Euphorbiaceae

16. Eucalyptus obliqua Eucalyptus Myrtaceae

17. Ficus bengalensis Bar Moraceae

18. Ficus glomarata Gular Moraceae

19. Ficus religiosa Pipal Moraceae

20. Mangifera indica Aam Anacardiaceae

21. Pongamia pinnata Venl Karanj Fabaceae

22. Populus tremula Popular Silicaceae

23. Salmalia malabarica Semal Malvaceae

24. syzygium cumini Jamun Myrtaceae

25. Terminalia indica Imli Combretaceae

26. Terminalia arjuna Arjun Combretaceae

27. Terminalia belerica Bahera Combretaceae

28. Zizyphus mauratiana Ber Rhamnaceae

1. Shrubs

2. Arbus prectatotrius Gunj Papilionaceae

3. Achyranthes aspera Apamarg Amarantaceae

4. Barleria cristata Koranta Acahthaceae

5. Calotropis procera Ak Asclepediaceae

6. Murraya Koenigii Mithaneem Rutaceae

7. Indigofera pulchella Neel Papilionaceae

8. Ipomea spp. Besharm Convolvulaceae

9. Lantana camara Raimunia Verbenaceae

10. Nyctanthes arbortristis Harsingar Oleaceae

11. Sida cardifolia Mamas Malvaceae

12. Vitex negundo Nirgudi Verbenaceae

13. Ricinus comunus Arandi Euphorbaiceae

Herbs

1. Argemone Mexicana Pilikateri Papaveraceae

2. Cassia tora Puar Caesalpiniaceae

3. Chenopodium album Bathua Amaranthaceae

4. Datura stramonium Datura Solanaceae

5. Euphorbia hirta Dudhi Euphorbiaceae




6. Indigofera caerulea - Fabaceae

7. Parthenium hysterophorus Gajarghas Asteraceae

8. Sida acuta Mahabala Malvaceae

9. Sida cordifolia Bala Malvaceae

10. Solanum surattense Bhatkataiya Solanaceae

11. Tridax procumbens Ghamra Asteraceae

12. Triumfetta pentandra - Tiliaceae

13. Vernonia cinerea Sahdevi Asteraceae

14. Xanthium strumarium Gokharu Solanaceae

Grasses & other

1. Cocculus hirsutus Chirenta Menispermaceae

2. Dioscorea oppositifolia - Dioscoriaceae

3. Ipomoea carica Railway creeper Convolvulaceae

4. Jasminum auriculatum Chameli Oleaceae

5. Pergularia daemia Sadowani Asclepiadaceae

6. Tinospora cordifolia Giloy Menispermaceae

7. Wattakaka volubilis Nakchikni Asclepiadaceae

8. Aristida adscensionis - Poaceae

9. Aristida funiculata Lapusari Poaceae

10. Chloris barbata Jarghas Poaceae

11. Cynodon dactylon Dub Poaceae

12. Heteropogon contortus Kusal,Lampa Poaceae

Medicinal Plants : The study area shows many medicinal plants. Many medicinal plants are also

observed in which Azadirachta indica; Aegle marmelos, Emblica officinalis, Ocimum are the

important one. List of medicinally important trees, shrubs and herbs and their uses with their

natural orders are presented in Table 3.20

Table 3.20 List of Medicinal Plants and their Medicinal Value

Sr. No.

Name of Species Family Medicinal Use

Trees

1. Aegle marmelos Rutaceae

Antidiuratic, antithetmintic, antipyretic,



Sr. No.

Name of Species Family Medicinal Use

carminative tonic

Furit used in chronic diarrhoea & dysentery

2. Azadirachta indica Meliaceae

Oil extracted from seed as local stimulant, insecticide and antiseptic

3. Cassia fistula Caesalpiniaceae

Control fever and gas trouble

Laxative

4. Emblica offcinalis Euphorbiaceae

Fruit powder coolent and laxative

Rich source of vitamin C

5. Ficus religiosa Moraceae

Quenches thirst

6. Mangifera indica Anacardiaceae

Controls stomach pain, diarrhoea, urine sugar

7. Syzygium cumini Mystaceae

Stem bark is used to treat sore throat, bronchitis, ulcer, dysentery

Seed powder for diabetes

8. Acacia nilotica Mimosaceae

In pharmacy, used in preparing emulsions, tablets, pills etc.

9. Calatropis procera Asclepiadaceae

Root bark used for leprosy

10. Argemone mexicana

Papaveraceae Latex is laxative and used in cataract

Seed oil used in asthma

Rare and Endangered Plant Species in the Study Area: In the study area, no rare and endangered

plant species was observed (Source: Red Data Book of Indian Plants, N.P Nayar and A. P. K.

Sastry, B.S.I. 1988).

3.10.2 Fauna

Most of the land around the study area (10 km radius around the project site) is under agriculture

and residential uses. No national parks, wild life sanctuary, biosphere reserve is present within 10

km area of the project site. No Reserve Forest and protected forests are present with in the study

area.

The information on fauna was collected by visual observations, random survey at different

locations and discussion with the local people. The secondary data from different Govt. Sources

and available literature was also referred in this study. The fauna study is carried for core zone as

well as for buffer zone i.e. 10 km area around the project site, which is describes in following

sections.

A. Fauna in Core zone: Proposed plant unit is already existing unit. No tree cutting is required. No major

vegetation is present within the core zone except Eucalytus plantation hence no wildlife exists within the

core zone. However, the presence of reptiles and amphibian species has been reported by the local

people. Common avifaunal species has also been observed in the core zone.



B. Fauana in Buffer Zone: List of fauna found in buffer zone (10 km study area) is provided in Table 3.3.

The listed fauna found in study area has been cross-checked with Red Data Book of Indian Animals

(Zoological Survey of India). There is no endangered or critical faunal species in the study area.

Mammals:

No significant carnivorous and herbivorous wild animals are found in the area. commonly found

mammals like Langurs (Semnopithecus entellus), Mongoose (Herpestes edwards) and Jungle Cat

(Felis chaus) are observed in the area. However, the presence of fox and hare has also been

reported in the area by the villager during public consultation. List of mammals observed in the

study area is provided in Table 3.22.

Amphibian & Reptiles (Herpetofauna)

Frog, Indian bull frog, snake like Indian cobra (Naja naja); Dhaman (Lycodon aulicus), and \lizard

is encountered at various places in study area (refer Table 3.22).

Table 3.21 : Mammalian Fauna reported in study area

S.No

Family Zoological name Local Name English Name Schedule

Class-Mammalia (Order: Primates)

1 Colobidae Presbytia entellus Langur Common langur II

2 Tupaiidae Suncus murinus Chuchundar Musk-shrew V

3 Pteropodidae Cynopterus sphinx Chamgader Short nosed fruit bat V

4 Pteropodidae Manis crassicandata Shehi Indian pangolin IV

5 Felidae Felis chaus Jangli Billi Wild cat II

6 Herpestidae Herpestes edwardsi Newala Mangoose II

7 Canidae Vulpes benglensis Lomadi Indian fox II

8 Sciuridae Funambulus pennanti Gilhaari Common squirrel IV

9 Muridae Bandicota bengalensis

Chuha Field rat V

10 Muridae Rattus rattus-refescena

Chuha Common house rat V

11 Hystricidae Hystrix Indica Shahi Common Porcupine IV *Conservation status is LC (Least Concerned species)

Table 3.22 : Reptiles and Amphibian observed in Study Area

S. N. Common Name Scientific Name Vernacular Name

Family Feeding Status

Schedule

Amphibians

1 Frog Rana tigrina - - C IV

2 Indian bull frog Hoplobatrachus tigerinus - - C IV

Reptiles

3 Binocellate cobra Naja naja Nag Elapidae C II

4 Indian Krait Bungarus coeruleus - Elapidae C IV



S. N. Common Name Scientific Name Vernacular Name

Family Feeding Status

Schedule

Amphibians

5 Russell‘s Viper Vipera russellis - Crotalidae C II

6 Rat snake Ptyas mucosus Dhaman Colubridae C II

7 Forest Lizard Calotes versicolor - Agamidae C II

8 House geeko Hemidactylis brukaii - Gekkonidae C II

Avifauna

Avifauna is an important part of the ecosystem playing the various roles as scavengers,

pollinators, predators of insect, pest, etc. They are also one of the bio indicators of different status

of environment and affected by urbanization, industrialization and human interference. They can

be used as sensitive indicators of pollution and malfunction of ecosystem.

Due to presence of the canal and other water bodies and favorable habitats for avifauna, wide

range of avifauna observed in the study area. The study area is inhabited by forty species of birds.

Among the birds recorded in this study, were insectivores and other dominating types included

omnivores, predators and granivores. The list of avifauna observed in the study area is given in

Table 3.23.

Table 3.23 : Avifauna Sighted during the primary survey

S

No

Hindi name English name Zoological name Schedule

1 Chota Basatha Barbet Negalaima haemacephla IV

2 Bhujang Black Drongo Dicrurus adsimilis IV

3 Kala teetar Black partridge Francolinus francolinus IV

4 Kabutar Blue rock pigeon Columba livia IV

5 Surkhab Braminy duck Tadorna ferruginea IV

6 Gaybagla Cattle egret Bubulcus ibis IV

7 Chota kilkila Common king fisher Alcedo atthis IV

8 Myna Common myna Aerodo therestristis IV

9 Bater Common or gray quail Coturnix coturnix IV

10 Cheel Common pariah kite Milvus migrans IV

11 Kera Common teal Anas crecea IV

12 Mokha Coucal Centropus sinensis IV

13 Papeha Cuckoo Cuculus varius IV

14 Sun Bulbul Flycatcher Monarcha azurea IV

15 Patringa Green bee eater Merops orientalis IV



16 Pilkiya Grey wagtail Motacilla caspica IV

17 Kauaa House crow Corvus splendens IV

18 Goraiya House Sparrow Passer domesticus IV

19 Hudhud Indian hoopoe Upupa epops IV

20 Gharfakhta Indian ring dove Streptopelia dicaocto IV

21 Kalchoori Indian Robin Saxicolides falicata IV

22 Saat Bhai Jungle babbler Turdoides striatus IV

23 Jungli Kauaa Jungle crow Corvus macrorhynchos IV

24 Koel Koel Endynamis scolopaceus IV

25 Badabagla Large egret Egretta chhaba IV

26 Pancaua Little cormorant Phalacrocorar niger IV

27 Kilchiya Little egret Egretta garzetta IV

28 Ullu Owl Bubo bubo IV

29 Dhoban Pied or White Wagtail Motacilla alba IV

30 Andha, bagla Pond heron Ardeola grayii IV

31 Jal murgi Purpule moorhen Gallinula chloropus IV

32 Jangali murgi Red jungle fowl Gallus gallus IV

33 Tituri Red wattled lapwing Lobivanellus indicus IV

34 Tota Rose ringed parakeet Psittacula krameri IV

35 Shikra Shikra Accipiter badius IV

36 Bulbul Small minivet Pericrocotuscinnamomaus IV

37 Chitta fakhta Spotted dove Streptopelia chinensis IV

38 Baya Weaver bird Ploceus philippinus IV

39 Kathfora Woodpeacker Dinopim benghalense IV

Threatened and Endangered Mammals

The listed fauna found in study area has been cross-checked with Red Data Book of Indian

Animals (Zoological Survey of India). There is no endangered or critical faunal species in the study

area.

3.11. Socio-Economic Environment

Demography of the District

As per Census of India- 2011, Barnala district had a total population of 5, 95,527 out of which 3,

17,522 are males and 2, 78005 are females. Males constitute the 53.31% and female constitutes

46.68 % of total population. Barnala has an average literacy rate 67.8% which is 7.5% more than

the 2001 Census data. The percentage of decadal growth in population has been 13.0% during

2001-11 and sex ratio (number of females per 1000) has been 876 in 2011 as compared to 872 in

2001 .In the district 0-6 years of population in the district has been 10.9 which is on the decreasing

trend in comparison of 2001 when it was 13.3% . As per the census records 2011, in Barnala

district there are 78.5% Sikhs, 19.0% Hindus, 2.2% Muslims, 0.1% Christians, Jains and

Buddhists are negligible.

Methodology



In order to assess the Demography & Socio-economic features of the study area, field surveys

through questionnaire filling and public consultations undertaken during the baseline field study

period. Village/Town wise census records 2011, for the study area falling mainly in Barnala District

of Punjab State was compiled and placed in the form of tabulation and graphical representation.

Purpose of the Study

As per provision of the EIA Notification, 2006, under the Environmental (Protection) Act, 1986,

expansion projects can be undertaken only after obtaining an Environmental Clearance (EC). Any

project seeking an environmental clearance requires an EIA report, prepared in accordance with

guidelines of Ministry of Environment & Forests (MoEF & CC), Government of India.

The construction phase of the project could lead to unplanned and haphazard development of

slums of various size and description with little or rudimentary. Socio-economic study was

conducted to establish the baseline demographic features and impacts due to upcoming

expansion project, as construction of any major industrial project invariably leads to Socio-

economic changes in its vicinity.

Description of Social Environment

Population Distribution within 2.0-km radial Zone of the Study Area

As per the census records 2011, the total population of the 2.0-km radial zone of study area was

observed as 2405 persons (100%) to the total population of one revenue village named Fatehgarh

Chhanna of Barnala tehsil & District of Punjab. Total number of ‗Households‘ was observed as 438

in the 2.0-km radius study zone. Male-female wise total population was recorded as 1231 males

and 1174 females respectively. Caste wise population distribution of the 2.0-km radial study zone

is shown in Table 3.24 as follows;

Table 3.24 : Caste-wise Population Distribution of 2.0-km Radial Study Zone

Name of Village

No of

Households

Total Population

Scheduled

Castes Scheduled

Tribes

Tehsil

Person Male Female Male Female Male Female

Fatehgarh Chhanna 438 2405 1231 1174 299 291 0 0 Barnala

Sub-Total (0-2km) 438 2405 1231 1174 299 291 0 0

Source-Census Records 2011

Population Distribution within 10.0-km radial Zone of the Study Area

As per the census records 2011, the total population of 10-km radius study area was recorded as

227740 persons of 24 revenue villages/towns of Barnala District in Punjab. All study area revenue

villages/towns are mainly under 2 tehsils namely Barnala and Tapa of Barnala District in Punjab.

Total number of ‗Households‘ was observed as 45918 in the whole study area. Male-female wise

total population was recorded as 122429 males and 105311females respectively.



There are only three towns named Barnala (MC), Handiaya (NP) and Dhanaula (MC) in the study

area comes under 2 tehsils namely Barnala and Tapa of Barnala district in Punjab. Caste wise

male-female population break-up of the entire study area villages/towns is shown in Table 3.25 as

follows;

Table 3.25 : Caste wise Population Distribution of 10-km Radial Study Area

Name of the Village

No of Households

Total Population Scheduled Castes

Scheduled Tribes

Persons Male Female Male Female Male Female

A-0-2km

Fatehgarh Chhanna 438 2405 1231 1174 299 291 0 0

B-2-10KM

Kaleke 1277 6804 3615 3189 1029 913 0 0

Dhanaula 1042 5593 3049 2544 512 477 0 0

Dangarh 486 2371 1265 1106 413 358 0 0

Rajgarh 207 1174 626 548 195 162 0 0

Pharwahi 955 5047 2700 2347 1175 1054 0 0

Rasulpur ……………………..Un-Inhabited Village……………

Dhanaula Khurd 1028 5406 2939 2467 732 650 0 0

Bhaini Jassa 536 2905 1587 1318 409 335 0 0

Jodhpur 640 3409 1785 1624 579 565 0 0

Khudi Kalan 961 5142 2784 2358 866 760 0 0

Patti Sohlan 101 523 282 241 147 135 0 0

Barnala (Rural) 1152 6077 3651 2426 1181 966 0 0

Dhaula 2008 10819 5772 5047 1843 1725 0 0

Barnala (MCl) 24490 116449 62554 53895 16096 14501 0 0

Handiaya (NP) 2702 12507 6810 5697 2592 2295 0 0

Dhanaula (MCl) 3878 19920 10521 9399 3662 3349 0 0

Rura Kalan 1162 6154 3249 2905 905 833 0 0

Dhurkot 1018 5473 2855 2618 900 755 0 0

Badra 513 2766 1481 1285 305 248 0 0

Kahneke 536 2655 1408 1247 243 199 0 0

Mehta 420 2304 1223 1081 513 412 0 0

Ghunas 550 2836 1537 1299 634 499 0 0

Khudi Khurd 256 1406 736 670 289 285 0 0

TOTAL (0-10km) 45918 227740 122429 105311 35220 31476 0 0

Source: Census Records 2011

Sex Ratio

The ‗Sex Ratio‘ is a numeric relationship between females and males of an area and bears

paramount importance in the present-day scenario where the un-ethnic pre-determination of sex

and killing of female foetus during pregnancy is practiced by unscrupulous medical practitioners

against the rule of the law of the country. It is evident that by contrast the practice of female

foeticide is not prevalent in the study area. There are 876 females for every 1,000 males in

Barnala district. The sex ratio for the children of 0-6 years of age is 843 female children per 1000

male children in the district. As per the census records 2011, the data reveals the sex ratio as 860

females for every 1000 males in the study area. The child sex ratio in the study area was observed

as 832 female children per 1000 male children (0-6years).

https://en.wikipedia.org/wiki/Women_in_India



The male-female wise population distribution of the study area is shown by graphical

representation in Figure 3.12 as follows;

Figure 3.12 Figure: Male-Female wise Population Distribution in the Study Area

Scheduled Caste & Scheduled Tribe Population

On the basis of the village/town wise SC & ST population distribution for the study area during

2011, the ‗Scheduled Castes‘ population was observed as 66696 consisting of 35220 males and

31476 females respectively which accounts as 29.3% to the total population (227740) in the study

area. No ‗Scheduled Tribes‘ population was observed in the study area. It implies that the rest

population out of the total population (about 70.7%) belongs to the General category.

Male-female wise SC & ST population distribution of the study area is graphically shown in Figure

3.13 as follows.

Figure 3.13 : Scheduled Caste Population in the Study Area



Literacy Rate

Literacy level is quantifiable indicator to assess the development status of an area or region. Male-

Female wise literates and illiterate‘s population is represented in Table 3.26 Total literates‘

population was recorded as 144370 (63.4%) in the study area. Data reveals that Male-Female

wise literates are observed as 81364 & 63006 respectively, implies that the ‗Literacy Rate‘ is

recorded as 63.4% with male-female wise percentages being 35.7% & 22.7% respectively. The

total illiterate‘s population was recorded as 83370 (36.6%) in the study area. Male-Female wise

illiterates were observed as 41065 (18.0%) and 42305 (18.6%) respectively. The Male-Female

wise graphical representation of literates & illiterates‘ population in study area villages/town is

shown in Figure 3.14.

Figure 3.14 : Male-Female wise Distribution of Literates & Illiterates

Table 3.26 : Male-female wise Literates & Illiterates

Name of the Village Total

Population

Literates Illiterates

Persons Males Females Persons Males Females

A-0-2km

Fatehgarh Chhanna 2405 1296 691 605 1109 540 569

B-2-10km

Kaleke 6804 3619 1980 1639 3185 1635 1550



Dhanaula 5593 3152 1820 1332 2441 1229 1212

Dangarh 2371 1423 835 588 948 430 518

Rajgarh 1174 682 387 295 492 239 253

Pharwahi 5047 2877 1627 1250 2170 1073 1097

Rasulpur ……………………..Un-Inhabited Village……………

Dhanaula Khurd 5406 3347 1924 1423 2059 1015 1044

Bhaini Jassa 2905 1533 890 643 1372 697 675

Jodhpur 3409 2038 1128 910 1371 657 714

Khudi Kalan 5142 3101 1787 1314 2041 997 1044

Patti Sohlan 523 295 167 128 228 115 113

Barnala(Rural) 6077 3492 2186 1306 2585 1465 1120

Dhaula 10819 5922 3309 2613 4897 2463 2434

Barnala (M Cl) 116449 80889 45254 35635 35560 17300 18260

Handiaya (NP) 12507 7181 4209 2972 5326 2601 2725

Dhanaula (M Cl) 19920 12477 6986 5491 7443 3535 3908

Rura Kalan 6154 3099 1718 1381 3055 1531 1524

Dhurkot 5473 2803 1511 1292 2670 1344 1326

Badra 2766 1475 835 640 1291 646 645

Kahneke 2655 1405 784 621 1250 624 626

Mehta 2304 1279 728 551 1025 495 530

Ghunas 2836 1439 828 611 1397 709 688

Khudi Khurd 1406 842 471 371 564 265 299

TOTAL (0-10km) 227740 144370 81364 63006 83370 41065 42305

Source: Census Records 2011

Economic Structure

The majority of people in rural sector are cultivators & agricultural labors which indicates dominant

agricultural economy. A small section of people are engaged as workers in household industries.

But in urban sector the existing scenario is completely reversed as most of the people there are

engaged in non-agricultural activity especially in local hotels/restaurants and as drivers some

people also operates their vans/jeeps/cars as tourist vehicle.

Annual income helps in identifying families below poverty line. During the field survey, income of a

household through all possible sources was recorded. Agriculture and allied activities was

reported to be the major source of income followed by non-farm wage labor, business, Govt. &

Pvt. Service etc. The other important sources of income include government pension and income

from selling of fodder.

Economy of the District



As per the district census handbook of 2011, the economy of the district is mainly based on the

agriculture & allied activities. Industry plays a key role in increasing the economy of the state and

further to districts and village levels. The district has also made a significant contribution in the

productivity of Cotton & Sugarcane. Forestry, Fisheries & Mining and Quarrying are also major

aspects contributing in the major economy of the district.

Workers Scenario (Occupation Pattern)

Occupational pattern was studied to assess the skills of people in the study area. Occupational

pattern helps in identifying major economic activities of the area. The main and marginal workers

population with further classification as casual, agricultural, households and other workers is

shown in Table 3.27. In the study area the Main and Marginal Workers population was observed

as 74644 (32.8%) and 6612 (2.9%) respectively to the total population (227740) while the

remaining 146484 (64.3%) were recorded as non-workers. Thus, it implies that the semi-skilled

and non-skilled work-force required in study area for the project is available in aplenty.

Table 3.27 Distribution of Work Participation Rate

Occupation Class 2011

Main Workers 74644 (32.8 %)

Male 65047 (87.1 %)

Female 9597 (12.9 %)

Marginal Workers 6612 (2.9 %)

Male 4135 (62.5%)

Female 2477 (37.5%)

Non-Workers 146484 (64.3 %)

Male 53247 (36.4 %)

Female 93237 (63.6 %)

Total Population 227740

Source: Census of India Records, 2011

9



Figure 3.15 : Workers Scenario of the Study Area

Table 3.28 Village wise Occupational Pattern in the Study Area

Name of Village MAIN

WORK_P MAIN_CL

_P MAIN_AL

_P MAIN_HH

_P MAIN_OT

_P MARG

WORK_P MARG_CL

_P MARG_AL

_P MARG_HH

_P MARG_OT

_P

A-0-2km

Fatehgarh Chhanna 711 394 129 10 178 25 5 4 1 15

B-2-10km

Kaleke 2319 973 495 145 706 221 37 76 6 102

Dhanaula 2299 1109 91 25 1074 45 4 2 0 39

Dangarh 576 287 144 24 121 197 10 95 6 86

Rajgarh 373 177 118 25 53 9 1 5 2 1

Pharwahi 1438 497 399 14 528 127 9 40 9 69

Rasulpur …………Uninhabited Village……………….

Dhanaula Khurd 1633 813 132 17 671 310 13 29 0 268

Bhaini Jassa 958 454 290 8 206 25 1 3 3 18

Jodhpur 1069 445 182 25 417 304 15 39 3 247

Khudi Kalan 1516 704 220 16 576 148 22 43 2 81

Patti Sohlan 105 33 14 23 35 87 5 7 10 65

Barnala(Rural) 2461 639 181 45 1596 134 22 18 3 91

Dhaula 4118 1338 691 59 2030 113 11 22 12 68

Barnala (M Cl) 37806 1858 1374 801 33773 2963 84 279 109 2491

Handiaya (NP) 3981 247 607 48 3079 234 3 111 6 114

Dhanaula (M Cl) 6184 1012 958 232 3982 487 22 160 42 263

Rura Kalan 2250 862 490 390 508 468 15 122 120 211

Dhurkot 1796 818 481 15 482 452 28 299 3 122

Badra 764 516 91 4 153 136 3 62 0 71

Kahneke 984 553 156 26 249 23 7 2 0 14

Mehta 572 319 112 11 130 105 9 29 2 65

Ghunas 1013 380 120 1 512 11 1 1 0 9

Khudi Khurd 429 274 17 3 135 13 0 1 0 12

TOTAL

(0-10km) 74644 14308 7363 1957 51016 6612 322 1445 338 4507

Source-Census Records 2011

List of Abbreviations

MAIN WORKERS POPULATION:

MAIN WORK_P : Main workers total population



MAIN_CL_P : Main cultivated labour population

MAIN_AL_P : Main agricultural labour population

MAIN_HH_P : Main workers population involved in household industries

MAIN_OT_P : Main other workers population

MARGINAL WORKERS POPULATION:

MARG WORK_P : Marginal workers total population

MARG_CL_P : Marginal cultivated labors total population

MARG_AL_P : Marginal agricultural labors population

MARG_HH_P : Marginal workers involved in household industries

MARG_OT_P : Marginal other workers Population

Composition of Main Workers

The ‗Main Workers‘ were observed as 74644 persons (32.8%) to the total population of the study

area and its composition is made-up of Casual laborers as 14308 (19.2%), Agricultural laborers as

7363 (9.9%), Household workers 1957 (2.6%) and other workers as 51016 (68.3%) respectively.

Composition of Main workers is shown below as Figure 3.16

Figure 3.16 : Composition of Main Workers Population

Composition of Marginal Workers

The total marginal workers are observed as 6612 which constitute 2.9% of the total population

(227740) comprise of Marginal Casual Laborers as 322 (4.9%), Marginal Agricultural Laborers as

1445 (21.9%), Marginal Household laborers as 338 (5.1%) and marginal other workers were also

observed as 4507 (68.1%) of the total marginal workers respectively. Details about marginal

workers in the study area are tabulated in Table.3.28. Composition of Marginal workers is shown

in Figure 3.17 as follows;



Figure 3.17 Figure: Composition of Marginal Workers

Composition of Non-workers

The total Non-workers population was observed as 146484 which constitute 64.3% to the total

population (227740) of the study area. Male-female wise Non-workers population was recorded as

53247 Males (36.4%) and 93237 Females (63.6%) respectively. Details about total Non-workers

population of the study area with Graphical representation are compiled in Table 3.29 and shown

by Figure 3.18 as follows;

Table 3.29 : Composition of Non-Workers

Non-Workers Population

Persons Males Females

146484 53247 (36.4%) 93237 (63.6%)



Figure 3.18 : Composition of Non-Workers

Availability of Basic Infrastructure Facilities & Amenities in the Study Area

A review of basic infrastructure facility and amenities available in the study area villages has been

done based on the field survey and Census Records 2011. As per the census records 2011, there

are a total of twenty-four (24) revenue villages/towns of Barnala District in Punjab state. All study

area revenue villages are mainly under two (02) tehsils namely Barnala and Tapa of Barnala

District respectively.

The study area has average level of basic infrastructure facilities (amenities) like educational,

medical, potable water, power supply, and transport & communication network etc; entire study

area is rural except three towns named Barnala (MC), Handiaya (NP) and Dhanaula (MC) of

Barnala district of Punjab State.

Education Facilities

There are about twenty-one (21) Primary Schools existing in the rural part of the study area.

Middle schools are found in 19 revenue villages of the rural part in the study area. Only thirteen

(13) Higher Secondary Schools were observed available in the rural part of the study area. Senior

Secondary School facility was observed available only in seven (07) revenue villages of the study

area. The educational facilities have been further strengthening now and several private public

schools and colleges are also functioning in the surroundings of the study area. Besides, there are

Engineering and Medical colleges available in Towns and District headquarters only. Higher

education facilities are available in Towns of the area. There is considerable improvement in

educational facility. The villages/towns of the study area have no such facilities can reach within

5.0 to 10.0-km range.

It is also mentioned that in the district there is one College of Engineering & Technology Viz. Arya

Bhatta College of Engineering & Tech. Village. Jodhpur Cheema, Teh. Barnala Baja Khanna

Road, (NH-71) in Barnala.

Medical Facilities

Medical facility is one of the most important facilities for people. Here we can see most of the

villages are far away from the hospital located. The medical facilities are provided by different

agencies like Govt. & Private individuals and voluntary organizations in the study area. As per the

census records 2011, only two (02) primary health center exists in rural part of the study area and

no community health center exists in the rural study area; most of the study area villages depend

upon the towns / district HQ of the study area having such facility. Seven (07) Primary health sub-

centers are exists in the rural part of the study area. Mother & child welfare center, Family welfare

center, Hospital and medical Dispensary facilities are observed in the four villages of rural part of

the study area; most of the villages are depending upon towns and district HQ having such type of

medical facility. Overall rural part of the study area is served by average medical facilities.

Specialized medical facilities are available in towns and District Headquarter (HQ) only.

From medical point of view in the district, there is 1 hospital in urban area, 1 CHC in rural and 3

CHC in urban area, 11 PHC in rural area, 35 Subsidiary Health Centers /Dispensaries in rural area

and 1 in urban area. Under the category of special medical institutions, there is 1 dispensary in



rural and 2 dispensaries in the urban area. In addition, there are also 12 Ayurvedic institutions in

the district.

Potable Water Facilities

Potable water facility is available in most of the villages/towns of the study area. Tube well water

facility was commonly observed in 15 (62.5%) villages of the study area. Hand pump facility for

drinking water was observed only in 8 villages of the study area. Out of the total twenty-four (24)

revenue villages/towns, no village was served with River/Canal water for drinking purpose in the

study area. As per the census records of 2011, no village was observed with Tank/Pond/Lake

water facility in the rural part of the study area. Adequate potable water facilities are available in

the study area.

Regarding, the position of villages covered under the rural drinking water supply scheme up to

3/2010 is concerned, in the district there are 124 inhabited villages, and all have been identified as

water scarcity villages, out of which in 117 village‘s water supply scheme have been

commissioned and in the remaining 7 villages scheme is still to be initiated. Thus, the percentage

of villages in this regard has been 94.4%.

Communication, Road, Transport and Banking Facilities

Apart from Post &Telegraph (P & T) services, transport is the main communication linkage in the

study area. As per the census records 2011, only one village named Dhanaula Khurd village of

Barnala district was observed with Post Office facility in the study area. Most of the villages are

depending upon those villages being served with such facility. The study area has good road

network, passes from the area.

Transport and Communication facilities are necessary for administrative purposes as well as

public convenience. Moreover; a well-knit public transportation system is a prerequisite for social

and economic development of the district. The linking of one place with other by road is very

essential to provide good transport system. Mainly four (04) towns named Dhanaula, Barnala,

Handiaya and Tapa are available within the distance range of 0 to 10kms from the villages of the

study area. More than >50% villages/towns are served with Pucca road facility in the study area.

As per the compiled information on basic infrastructure facility, about 33% villages in the study

area are being served with Public Bus services. Only two villages named Barnala (Rural) and

Ghunas were observed with railway station facility in the study area and remaining villages are

depending upon towns and concerned district HQ for such facility. Nearest State/National Highway

are as SH-13 (1.01km, West) & NH-64, 3.47km, North respectively from the project site. There is

no airport facility in this district. The nearest airport is Sahnewal Airport (LUH/VILD), located at

85km away from the district HQ in Punjab. The study area has almost all the schedule commercial

banks with ATM facility in urban areas and the district HQ.

Power Supply

It is revealed from the compiled information on amenities availability as per the census record of

2011; almost all villages and towns (about 92%) are electrified for all purpose in the study area.

Electricity is one of the chief importance necessities for the economic development of the district.



Village/town wise ‗Basic Infrastructure and Amenities’ availability data for the entire study area is

represented in Table 3.30 as follows;



Table 3.30 Village wise Basic Amenities Availability

Name of the Village Educational Medical Drinking Water Communication

& Transport

Approach to the

Village

Power Supply Nearest Town

P M SS SS

S

P

H

C

P

H

S

C

M

C

W

C

Al.

H

D F

W

C

T W H

P

TW P

O

Mo

b.

BS RS P

R

KR NW F

P

E

D

E

A

g.

E

C

EA

Kaleke 1 1 1 1 0 0 1 1 1 1 2 2 1 1 2 1 1 2 2 1 2 1 1 1 1 1 DHANAULA

Dhanaula 1 1 0 0 0 0 0 0 0 0 1 2 2 1 2 2 1 2 1 1 2 1 1 1 1 1 BARNALA

Dangarh 1 1 1 1 1 0 0 1 1 0 1 2 1 1 2 1 2 2 2 1 2 1 1 1 2 1 DHANAULA

Rajgarh 1 1 0 0 0 0 0 0 0 0 2 2 2 2 2 1 2 2 2 1 2 1 1 1 1 1 BARNALA

Pharwahi 1 1 1 1 0 1 0 0 0 0 2 1 1 1 2 1 2 2 2 1 2 1 1 1 1 1 BARNALA

Rasulpur BARNALA

Dhanaula Khurd 1 2 0 0 0 0 0 0 0 0 2 2 1 1 1 1 1 2 2 1 2 1 1 1 1 1 HANDIAYA

Bhaini Jassa 1 1 1 0 0 0 0 0 0 0 2 2 1 1 2 1 2 2 2 1 2 1 1 1 1 1 HANDIAYA

Fatehgarh Chhanna 1 1 1 0 0 1 0 0 1 0 2 2 2 1 2 1 2 2 1 1 2 1 1 1 1 1 HANDIAYA

Jodhpur 1 1 1 1 0 0 0 0 1 0 2 2 2 1 2 1 2 2 1 1 2 1 1 1 1 1 HANDIAYA

Khudi Kalan 1 1 1 1 0 1 0 0 0 0 1 2 2 2 2 2 1 2 1 1 2 1 1 1 1 1 HANDIAYA

Patti Sohlan 1 0 0 0 0 0 0 0 0 0 2 2 2 2 2 2 2 2 1 1 2 1 1 1 1 1 BARNALA

Barnala(Rural) 1 0 0 0 0 0 0 0 0 0 1 2 2 2 2 1 2 1 2 1 2 1 1 1 2 1 BARNALA

Dhaula 2 1 1 1 0 0 0 0 1 0 1 2 2 1 2 1 1 2 1 1 2 1 1 1 1 1 BARNALA

Rura Kalan 1 1 1 1 1 1 1 0 1 0 1 2 2 1 2 1 1 2 1 1 2 1 1 1 1 2 TAPA

Dhurkot 1 1 1 0 0 1 1 0 1 1 1 2 2 2 2 1 2 2 1 1 2 1 1 1 1 1 TAPA

Badra 1 1 1 0 0 0 0 0 1 1 1 2 1 1 2 1 2 2 1 1 2 1 1 1 2 1 TAPA

Kahneke 1 1 1 0 0 0 0 0 0 0 1 2 2 1 2 2 2 2 2 1 2 1 1 1 1 1 TAPA

Mehta 1 1 0 0 0 0 0 0 0 0 1 2 2 1 2 2 2 2 1 1 2 1 1 1 1 2 TAPA

Ghunas 1 1 0 0 0 1 1 0 0 1 2 2 1 1 2 1 1 1 1 1 2 1 1 1 1 1 TAPA

Khudi Khurd 1 1 1 0 0 1 0 0 1 0 1 2 1 1 2 1 1 2 1 1 1 1 1 1 1 1 TAPA



Barnala (M Cl) …………………………….Town Area……………………………

Handiaya (NP) …………………………….Town Area……………………………

Dhanaula (M Cl) …………………………….Town Area……………………………

TOTAL 21 19 13 07 02 07 04 02 09 04 Status for Availability and Non-Availability is shown as A (1) & NA (2) respectively

Source-http://www.censusindia.gov.in/2011census/dchb/DCHB.html

Abbreviations:

Educational Facilities: P-Primary School, M-Middle School, SS-Higher Secondary Schools, SSS- Senior Secondary School

Medical Facilities: CHC-Community Health Centre, PHC-Primary Health Centre, PHSC-Primary Health Sub-Centre, MCWC-Maternity and Child Welfare Centre, H-Hospital, D- Dispensary, FWC-Family Welfare Centre

Drinking Water Facilities: T-Tap Water, W-Well Water, HP-Hand Pump, TW-Tube Well Water, R-River Water, Tk-Tank Water, O-Other Drinking Water Facility

Communication and Transport Facilities: PO-Post Office, SPO-Sub-Post Office, PTO- Post & Telegraph Office, Tel.-Telephone Connection, Mob.- Mobile Phone Coverage, BS-Bus Services, RS-

Railways Services

Approach to Village: PR- Paved Roads, KR-Kuchha Road, FP-Foot Path

Power Supply: ED-Power Supply for Domestic use, E Ag.- Power Supply for Agricultural use, EC-Power supply for Commercial use, EA-Electricity for All Purposes



Brief Description of Places of Religious, Historical or Archaeological Importance and

Tourist interest in the Villages & Towns of the District;

Barnala is the headquarters of the Barnala District and is an Indian city in Punjab. This place lies

in the middle of the state and is well known for its warm culture. This place is located on the

highway no 13, Sirsa-Ludhiana highways also pass through Barnala. This place is at 85 km from

Ludhiana and 65 km from Bhatinda.

Gurudwara Arisar Sahib Patshahi IX

The distance of this Gurudwara from Tapa Railway Station is 10 km. From Barnala city, it is 11

km and 3 km from Mansa-Barnala Road in Village Dhaula.

Gurudwara Gurusar Pakka Sahib Patshahi IX

This Gurudwara is at a distance of 7 km from the Bhatinda-Sangrur Road, Bhatinda City. It is

southwest, 6 km of Barnala city.

Gurudwara Patshahi IX, Dhilwan

The distance of this Gurudwara is 4 km from Tapa Railway Station, 25 km from Barnala City.



CHAPTER 4. ANTICIPATED ENVIRONMENTAL IMPACTS AND MITIGATION MEARSURES

4.1. General

In this chapter, we:

Identify project activities that could beneficially or adversely impact the environment

Predict and assess the environmental impacts of the such activities

Identify possible mitigation measures for these project activities and select the most

appropriate mitigation measure, based on the reduction in significance achieved and

practically in implementation

For proper assessment of significance and magnitude of environmental changes due to

construction and operational phases of the plant, the impacts are analyzed in the 10 km radius of

study area around the proposed plant site for each environmental parameter. Impact

assessment study for the existing unit is carried out by predicting net contribution of pollutants

(qualitative as well as quantitative) on overall qualitative assessment of various environmental

indicators. Prediction of impacts is an important component in environmental impact assessment

process. Several techniques and methodologies are in vogue for predicting the impacts due to

existing and proposed industrial development on physico -ecological and socio-economic

components of environment. Such predictions delineate contribution in existing baseline data for

the operational project and superimpose over the baseline (pre-project) status of environmental

quality to derive the ultimate (post-project) scenario of the environmental conditions due to the

proposed project. The quantitative prediction of impacts leads to delineation of suitable

environmental management plan needed for implementation during the construction and

operational phases of the proposed project to mitigate the adverse impacts on environmental

quality.

4.2. Construction Phase

The activities of proposed program will be confined to the project site within the boundary of

Plant complex. The proposed project will not cause any significant loss of any important flora.

4.2.1. Air Environment

The potential impact on air quality due to proposed expansion project will be temporary rise in

particulate emission level likely to result from

Fugitive dust emissions at the construction site

Use of unpaved roads and truck tracks by the construction activities

Operation of the concrete, asphalt and hot mix plants

These pollutants can affect the surrounding vegetation and nearby agricultural crops. It‘s an

expansion project within existing premises and construction activity is limited only to the project

site and hence unlikely to cause any change in the ambient air quality around the proposed

project. As the emission level is very low and intermittent, quantitative predictions are not

possible due to limitations of the dispersion model. Therefore, considering all the air pollutants, it



is not expected that air emissions due to construction will exceed air quality standards

(NAAQMS).

There might be some impact on air quality that may take place during construction, which would

be caused by emission of dust during excavation as well as from the earth material stored at the

site. The potential for dust in the form of particulate matter to be emitted during construction

strongly depends on the type of activities taking place, such as the movements of vehicles,

speed, soil stripping, excavation, back filling and reinstatement. Sprinkling water on the

deposited earth material shall minimize emissions of particulate. The rate of emission of dust, its

predicted rates of deposition and the temporary nature of the dust generating activities is

expected to be well within acceptable limits. Also, vehicles transporting earth and other

construction material to the site will be covered to ensure their dust particles do not escape into

the air. During construction all earth material will be kept covered to minimize impact on the

ambient air quality.

Traffic to the site during construction will be slightly more intensive than at present. However,

well connectivity State Highway 13 will not have any significant stress on the traffic. The present

road conditions are good for the proposed additional movement of vehicular traffic.

Hence the impacts on the ambient air quality during construction phase will be temporarily for

short duration and reversible in nature and restricted to small area.

4.2.2. Operation Phase

Prediction of ground level concentration (GLCs) due to proposed project has been made by

using air dispersion model as per CPCB Guideline.

1. The pre-project (baseline) ambient air quality status in the study area indicates that all the

criteria pollutants except PM (due to local phenomenon) are well within the prescribed

National Ambient Air Quality Standards (NAAQS) for industrial, residential, rural and other

areas.

2. The ambient air quality with respect to air pollutants will change during the operation phase of

the proposed project. However, adequate stack height will be provided for better dispersion of

flue gas as per the guidelines of CPCB. In addition to that, adequate greenbelt will be

developed for further control of air pollution.

3. To assess the impact of air emissions from various continuous point sources, air dispersion

modelling study has been conducted with the help of Industrial Source Complex Short Term

Model (ISCST3) View 6.2 model of Lakes Environmental. Detailed description has been given

in the following sub-sections:

4.2.3. Model Details



1. Air dispersion modelling can be used to predict atmospheric concentrations of pollutants at

specific locations (receptors) over specific averaging times (i.e. annual, daily, and hourly). An

atmospheric dispersion model accounts for the emissions from a source; estimates how high

into the atmosphere they will go, how widely they will spread and how far they will travel

based on temporal meteorological data; and outputs the pattern of concentrations that will

occur for various exposure periods, thereby providing the exposure risks for different

receptors.

2. In the proposed project, prediction of impacts on air environment has been carried out

employing mathematical model based on a Steady State Gaussian Plume Dispersion Model

designed for multiple point sources for short term. In the present case, Industrial Source

Complex Short-term [ISCST3] dispersion model based on steady state Gaussian Plume

Dispersion, designed for multiple point sources for short term and developed by United States

Environmental Protection Agency (USEPA) has been used for simulations from point sources.

3. The predictions for air quality during operation phase were carried out for particulate matter

less than 10 microns (PM10), particulate matter less than 2.5 microns (PM2.5) and Hydrogen

Bromide (HBr), Hydrochloric acid (HCl), Chlorine (Cl2) and many more concentrations using

ISCST3.

4. The options used for short-term computations are:

5. The plume rise is estimated by Briggs formulae, but the final rise is always limited to that of

the mixing layer

6. Stack tip down-wash is not considered

7. Buoyancy induced dispersion is used to describe the increase in plume dispersion during the

ascension phase

8. Calms processing routine is used by default

9. Wind profile exponents is used by default

10. Flat terrain is used for computation

11. Pollutants do not undergo any physico-chemical transformation

12. No pollutant removal by dry deposition

13. Universal Transverse Meter (UTM) coordinates have been used for computation

A uniform polar grid was used for the computation and extended to 10 km from the

center of the proposed project. In addition to that, receptors were also placed at the

sampling locations

4.2.4. Predicted GLC due to Proposed Project



The main sources of air pollution due to the operation of the plant are the Boiler and Process

stack. The contribution to GLCs for the pollutants i.e. particulate matter, SOx, NOx, HCl, etc.

were predicted over the study area proposed project considering the worst scenario. The

emission load from proposed project is given in Table below. The prediction (maximum) is based

on the expected total emission rate from each stack and are given in isopleths Figure 4.1 (A, B,

C and D) for proposed project. The additional contribution to GLC is also given below in Table

4.1.

Table 4.1 : Stack emissions

S.

n

Description Ht.

(m

)

Dia.

(m)

Vel.

(m/s

)

Tem

p

(0C)

Flow

Rate

Emission rate

(g/s)

nM³/hr SP

M

NO

x

HCL


5

5.73 75 25271.5

2

1.05 2.11 -

2 boiler 32 tph 60 1.5 12.2 80 65487.1

5

2.73 5.46 -


5

6.7 85 48267.6

7

2.01 4.02 -

4 Furnace 1500000 Kcal/hr 28 0.5 5 200 2225.55 0.03 - -

5 2 X Furnace 2000000 Kcal/hr 24 0.5 2 200 890.22 0.01 - -

6 5 X Furnace 200000 Kcal/hr 16 0.2

5

4.3 200 478.49 0.01 - -

7 IBAP Scrubber 16 0.2

5

4.3 35 478.49 0.01 - 0.00

8 Acetyl Scrubber 16 0.25

4.3 35 478.49 0.01 - 0.001

9 PAC Scrubber 16 0.25

4.3 35 478.49 0.01 - 0.001

10 M-phenoxybenzaldhyde/Vanillin/ATTBA/Losatan potassium/ Methyl – 2- amino- 3 – chloro propionate HCL/ 4 amino benzamide/P-nitrobenzyl chloride

16 0.25

4.3 35 478.49 0.01 - 0.001

4.2.5. Meteorological Data

The meteorological data consists of wind speed, direction, temperature, humidity, solar

radiation, cloud cover and rainfall recorded during the months of mid-March 2018, through mid-

June 2018, on an hourly basis. Wind speed, wind direction and temperature have been

processed to extract the 24–hour mean meteorological data for application in ISCST3.

4.2.6. Receptor Locations

A total of about 728 receptors – 720 receptors of which were generated with a polar grid from

the canter of the proposed project and extended to 10 km. Apart from these receptors, the

sampling locations were also considered to assess the incremental load on the baseline

environmental scenario.

4.2.7. Summary of Predicted GLC’s



The summary of maximum ground level concentrations (GLC) for the proposed project is listed in Table

4.2.

Table 4.2 : Summary of Maximum 24-hour Incremental GLC due to the Proposed Project Stacks

Parameters Maximum incremental GLC (µg/m³)

Distance (Km)

Direction

PM 0.95 1.6 SE

SO2 0.64 1.6 SE

NOx 3.1 1.6 SE

HCL 0.23 1.6 SE (Source: Modelling output results)

Maximum 24 hourly average incremental in GLCs of PM, SO2, NOx and HCl due to proposed expansion

project during operation phase are predicted and given in Table 4.2. The isopleths of the pollutant

concentration due to the impacts associated with the operation of the proposed project are shown in

Figures 4.1 through 4.4 for PM, HCl, SO2 and NOx respectively. Contours of the incremental GLCs depict

that the travel of emissions from the proposed project would be mainly in SE, quadrant.

Besides the worst GLC (maximum) predictions the GLC incremental at the sensitive receptors (where the

ambient air monitoring was carried out) was also predicted. The predicted incremental GLC for pollutants

are given in underneath Table 4.4.

Table 4.3 Ambient Air Quality Monitoring Results (24-hour average)

Location Distance

/Direction

PM(g/m3)

Existing baseline

Mean

Incremental

GLCs

Net Incremental

GLCs

Project Site 00 88 0.19 88.19

Fatehgarh Chhanna

1.68km,SE 92 0.95 92.95

Kaleke 7.12km,SE 89 0.39 89.39

Dhanaula 7.56km,SE 85 0.39 85.39

Dhaula 3.84km,SW 87 00 87.00

Ghunas 7.88km,NW 85 00 85.00

Handiaya 4.90km,N 90 00 90.00

Barnala 8.87km,NE 93 00 93.00

Table 4.4 Ambient Air Quality Monitoring Results (24-hour average)

Location Distance SO2(g/m3) NOx(g/m3)



/Directio

n

Existin

g

baselin

e Mean

Incrementa

l GLCs

Net

Incrementa

l GLCs

Existin

g

baselin

e Mean

Incrementa

l GLCs

Net

Incrementa

l GLCs

Project

Site 00 12.7 0.13 12.83 26.4 0.63 27.03

Fatehgar

h

Chhanna

1.68km,

SE 11.8 0.61 12.41 22.7 3.1 25.8

Kaleke 7.12km,

SE 10.9 0.13 11.03 23.2 1.25 24.45

Dhanaula 7.56km,

SE 11.4 0.13 11.53 21.1 1.25 22.35

Dhaula 3.84km,

SW 12.5 00 12.5 23.8 00 23.8

Ghunas 7.88km,

NW 11.0 00 11.0 21.6 00 21.6

Handiaya 4.90km,

N 12.7 00 12.7 23.0 00 23.00

Barnala 8.87km,

NE 12.2 00 12.2 27.4 00 27.4



Discussion of the Cumulative Impacts at monitoring locations:

The nearest settlement in downwind direction is Fatehgarh channa village (towards SE) at 1.68 km. As

per baseline data of mean AAQ for PM at Fatehgarh channa village is 92 µg/m³ and with this proposed

project, 0.95 µg/m³ rise in GLCs so PM level will be 92.95 µg/m³. The Particulate Matter in the study area

is contributed mainly by commercial activities and traffic movement (vehicular emissions), re-suspended

dust from paved and unpaved roads and open uncovered areas as well as from industrial activities. It can

be concluded that with the proposed project all the mean PM Concentration will remain within the NAAQ

norms.

Maximum baseline GLC for SO2 (Process and utilities) at downwind direction (SE) was as 11.8 µg/m³

observed at Fatehgarh Channa village. With this proposed expansion project SOx level may increase by

0.61 µg/m³ so post project level of SOx is 12.41µg/m³. Maximum baseline GLC for NOx was as 22.70

µg/m³ observed at Fatehgarh channa village. With this proposed project NOx concentration is 3.1 µg/m³

so rise in GLC of NOx concentration is 25.80 µg/m³. It can be concluded that with the proposed project all

the AAQ parameters will remain within the NAAQ norms.

As is evident from the table and discussion above, there will be no adverse impacts on the surrounding

area (all pollutants post project GLC will be well within NAAQ norms except PM which is already high due

to natural and other commercial and traffic causes). Highly efficient air pollution control systems have

been adopted to mitigate particulate matter as well as gaseous emissions in the ambient environment.



(Source: Modelling output)

(A) Isopleth for PM incremental GLC due to Proposed Project




(B) Isopleth for SO2 incremental GLC due to Proposed Project




(C) Isopleth for HCl incremental GLC due to Proposed Project




(D) Isopleth for NOx incremental GLC due to Proposed Project


4.3.1. Construction Phase

During construction phase, there will be noise generation due to use of bulldozers, JCB, vehicle

movement, vibrators, heavy fabrication work for erecting major plant equipment including crane,

hydra, DG sets, etc. Although there is no specific noise-sensitive fauna has been recorded near

to project site (and project site is in Industrial area) but limited avifauna and small animals in the

industrial area can be affected by increased noise level. In such cases they can change their

habitat. The noise will be localized and will be intermittent, temporary, short term, direct,

naturally reversible during construction stage and hence no significant impact is envisaged.




The main source of noise generation during operation stages are mainly from pumps, blowers, compressors, DG sets, vehicle movement for transportation of raw materials, finished goods etc.

Noise level contributed from light medium and heavy vehicles on the roads can be considerable depending upon the traffic density. The heavy commercial vehicles traffic is limited depending upon the material receipt and dispatch of synthetic organics through road transport. But this noise will be intermittent and temporary. It is expected that noise level at the plant boundary and other 8 locations will be within the prescribed norms of CPCB due to operation of the proposed project and no significant impact on noise environment is expected. Also, the noise will not be audible beyond its boundary limit, particularly due to natural green belt and other attenuators.

4.4. Water Environment

4.4.1. Construction Phase

During construction, water will be needed mainly for construction and domestic purpose i.e. for drinking and sanitation. Drinking and sanitation facilities shall be provided to workers during construction. Water will also be needed for sprinkling to reduce dust emission, if any.

The water required in the above activities will be only a fraction of total water required. Moreover, this requirement will be irregular and limited to construction phase only and hence no impact is envisaged during construction phase. The domestic wastewater generated will be send to existing ETP and hence no impact is envisaged.


Water requirement will be made available through Borewell/surface water. Wastewater will be segregated into two streams as High TDS / High COD (HTDS) and Low TDS / Low COD (LTDS). The HTDS Effluent stream after neutralization, filtration will be sent to Multi Effect Evaporator (MEE). The distillate water will be treated in ETP along with LTDS effluent. The concentrate will be sent to ATFD for drying. The dried salt will be sent to approved TSDF for final disposal. The ETP treated effluent will be send for plantation. The RO reject (from blow down of boiler and cooling tower) will be send to MEE. No process effluent will be discharged outside the plant premises. The provision of stripper for recovery of solvent (VOC) from HTDS effluent before MEE. The inorganic hazardous residues will be sent to TSDF.

There will not be any discharge of wastewater on the land. Besides, there will be separate storm water and industrial wastewater drains to eliminate chances of mixing of rainwater withwastewater. Hazardous wastes will be stored, managed and handles as per hazardous wastes rules. All bulk chemicals and fuel storage areas will be provided with dyke wall / bunds to eliminate chances of any spillages/ leakages entering into the storm water drain.

No significant adverse impact on the surface and ground water or soil quality is envisaged in viewof the proposed mitigative measures.

4.5. Land Environment



Site Preparation leading to Change in Land Use

During Construction phase

Change in Land use\Landcover. Present land use of the project site is industrial land.

Change in land use\Landcover outside the plant area.

Removal of Vegetation

Alteration of Topography

Construction material remain after completion of work

Surrounding area of the project site is agricultural land so generation of Dust can lead to the

degradation of agricultural land.

During Operation Phase

Generation of domestic, Solid (non-hazardous) and Hazardous Waste

Discharge of sewage or other effluents on nearby land.

Handling, storage, use or spillage of hazardous materials

Mitigation measures during construction and operation

The proposed expansion will be done within existing premises and lands are already under possession of IOLCP. So, there will not be any change in land-use due to proposed project. For this expansion project workers shall be hired locally hence there will be no labour colonies are proposed so there will be no landuse/ lancover change outside the plant area. During construction, top soil generated from various activities like excavation etc will be stored and preserved to use it during restoration period as far as possible. There will be neither removal of any vegetation & nor disposal of wastewater on land. The construction and demoliation waste will be disposed as per Construction and Management rules 2016. To avoid the dust emission, unit shall ensure that water sprinkling is regularly carried out during construction activities. Hazardous wastes will be stored at earmarked area with impervious flooring, shed and spillage/ leakage collection system to eliminate rainwater contamination, chances of overflow / spillages going on to the land and thus land/ soil contamination. Hazardous wastes will be disposed as per the Hazardous Waste Rules. Disposal mechanism of Hazardous wastes has been mentioned in the Section 2.10.

The storage and handling of raw materials shall be done properly to prevent any spillage. The hazardous waste generated during the operation phase, will properly disposed so that there is no spill and contamination of land. The hazardous waste will be disposed as per Hazardous waste rules 2016.

4.6. Biological Environment

Though the concentrations of the emitted pollutants will be kept within permissible levels through

the various engineering controls, it is essential to have eco-management in the Likely Impact

Zone for safeguard and enhanced of ecological environment of the project area. The likely

impacts and mitigation measures associated with different phases due to various project

activities area describes in following Table.



Project Aspect

Description

Likely Impacts

on Ecology and

Biodiversity (EB)

Impact

Consequence -

Probability

Description /

Justification

Mitigation

measures

Type

Pre-Construction Stage Impacts

Removal of site

vegetation like

herbs, shrubs and

grasses

site specific loss of common floral diversity

the site is already levelled

No vegetation is present

No threat of loss of faunal diversity as no faunal species reported at site.

IOLCP has

already developed

a dense greenbelt

/ all around the

project premises.

Short term

Construction Stage Impacts

Dust and Noise

Generation due to

movement

of JCBs, other

machinery, and

other construction

activities

Dust settlement on

vegetation

Disturbance to

faunal species is

surroundings

No endangered

fauna reported form

the site as well as

in study area.

The species

reported from

project site and

buffer zone are

common /

generalist species

and not very

sensitive to the

routine activities, so

there will be no

threat of facing

disturbance.

Subject to periodic

monitoring and

surveillance.

Water sprinkling

for Dust

suppression.

Construction

activities shall be

restricted in night

time.

Short term

Operation Stage Impact

Emission of PM,

SO2, NOx due to

operation (Indirect

impact on crops,

trees and shrubs

of vicinity

due to

contamination of

ambient air, dust

emission,

Impact on

surrounding

vegetation and

associated

biodiversity.

Though the

emission levels of

all pollutants will be

kept within

permissible limits.

APCD shall be

used to control dust

emissions from

various sections of

plant.

Operation subject

to management by

operational

controls. Emission

levels of all

pollutants will be

kept

within permissible

levels through

various

Long term

(insignificant)



vehicular exhaust) Modeling studies

proves that the

incremental air

pollution will not

violate the air

quality standards.

Proposed plant is

zero liquid

discharge basis so

no waste water will

be discharged.

greenbelt already

exits. Such

measures will be

adequate to protect

the noise and air

pollution impacts.

engineering

control measures.

However, green

belt development

with suitable

species will help to

mitigate likely

cumulative

impacts.

Noise Generation

(Disturbance to

sensitive terrestrial

fauna due to

noise pollution)

Construction Stage Impacts

Excavation and filling up operation may results in fugitive dust emission. The dust deposition on

pubescent leaves of the surrounding vegetation may leads to temporary reduction of

photosynthesis. Such impacts would however be confined mostly to the initial period of the

construction phase and would minimized through paving of roads, surface treatment, regular

water sprinkling in dust generating areas and greenbelt development. The impact on the ecology

of the surrounding area during the construction stage will be insignificant in nature. Greenbelt

development along the plant boundary, further development of gardens and lawns near admin

building will mitigate the residual impact on natural resources.

Operation stage Impacts

No national park, wildlife sanctuary, biosphere reserve exists within 10 km area of the project.

No endangered or rare or threatened plant or animal species was observed within 10 km area of

the project site.

The impact on the surrounding ecology during the operation of the project will mainly occur from

the deposition of air pollutants. Air pollution affects the biotic and abiotic components of the

ecosystem individually and synergistically with other pollutants. Chronic and acute effects on

plants and animals may be induced when the concentration of air pollutants exceeds threshold

limits. Particulate emission and other gaseous emissions from the proposed plant are the major

pollutant that may affect the ecology of the area. However, the AAQ modeling proves that in

worst condition the concentration of the PM and other gaseous emission will not exceeds the

AAQ standards. Further the mitigation measures have been suggested for the same. By

adopting the mitigation measures suggested the impact due to operation of the proposed

expansion will be negligible.

4.7. Socio – Economic Environment



Proposed expansion project will generate employment opportunities some through direct employment and

more so indirectly through services for the plant.

Positive Impacts due to Proposed Expansion Project

Construction Phase

Expansion will be done within the existing site occupied by industry. There is no

permanent or temporary change in land use.

The site has existing tree plantation on periphery of the plant and along the roads.

The local infrastructure and facilities in the area will be further developed and people

will be benefited directly or indirectly.

The unit is awarded with the ―National Energy Conservation Award‖ Consecutively for

the years 2005, 2006, 2007, 2008, 2009,2010,2011,2012,2013,2014,2016 by Ministry

of Power, Government of India.

The unit is awarded with National Level ―Green Chemistry Award‖ for Innovation to use

dual technology for the production of Mono Chloro Acetic Acid and Acetyl Chloride in a

single Plant by the Govt. of India.

Short term positive impacts will result in better quality of life. No labour camp will be

established at site as labours will be hired from local area.

Proposed project will generate the employment on various levels time to time and

gives the priority to local persons.

The living conditions of the people will not be affected. There will be employment

generation for nearby area people get positive impact.

The total employee after expansion will be 1850 persons and Local people will be given preference wherever found suitable for all the jobs in the plant, direct as well as indirect.

The greenbelt area development will help in enhancing the aesthetics of the proposed

Greenfield project.

The construction activities and development will make the area an attractive place for

people to move in or return to the area.

Economic status of the local people will improve due to the increased business

opportunities, thereby, making a positive impact.

Thus, the proposed project will have significant positive impact on the employment

pattern of the study area.

Expansion will be done within the existing site occupied by industry, and no R & R

issue observed for the proposed project.

Operational Phase

Educational, medical and housing facilities in the study area will considerably improve.

Adequate systems shall be provided to capture the emissions from process plants &

maintain the emission quality as per recommended guidelines with scrubber having

caustic solution, before venting it into the atmosphere.

The site is well connected by road and rail network and has advantage of good

infrastructure facilities like National & State Highway roads (SH-13, (1.01km, W) & NH-

64, 3.47km, N), water, power etc;



Infrastructure development i.e. road & commercial building construction in the area

due to proposed expansion activities.

The project will be beneficial to local people as the company progress and expands its

activity gradually.

More revenue will be generated to the Government.

Negative Impacts due to Proposed Expansion Project

During construction and operational phase noise will be generated due to traffic influx

in the company premises due to material and personal transport. But it will be minimal

and for a short term only.

Dust and other emissions are expected during construction phase and local people

may be affected.

Improper management of waste material from the proposed activities may affect the

local peoples.

Due to Noise generation during the operation phase of the proposed project, local

people may be adversely affected.

Mitigation Measures for Negative Impacts due to Proposed Expansion Project

Increase in population density in core zone study area due to workforce involvement

during construction phase is only for short term impact.

Adequate Pollution controlling equipments with higher efficiancy shall be attached with

proposed stacks.

The project proponent/contractors shall ensure that most of the workforce shall be

engaged from the nearby villages/town.

The transportation of raw materials will be done by trucks as per MSIHC rule.

Suitable dust suppression techniques will be adopted, such as water sprinkling will be

taken.

The inorganic hazardous residues will be sent to TSDF.

The impact is likely to be for short duration and confined locally to the construction site

itself.

The overall project will have a long term benefit and hence no mitigation measure is

required.

4.8. Infrastructure

The raw material (solid, liquid and also gaseous etc.) will be transported from suppliers

approximately 3 to 5 trucks/ day will come to the plant. The final product (APIs/intermediate) will

be dispatched from plant to various parts of the country through the State and National high way

and railways, for which nearly 14 to 15 small vehicles will be used for the same. Based on the

estimation, approximately 2-3 vehicles per day will remain at the project site. Hence, due to the

project activities the increase in the vehicular traffic density in the study area will be negligible.

However, adequate parking facility provided the project site along with rest room and canteen

facilities within the premises of the factory for drivers will be provided. The project site is only

about 0.81 km away from State Highway (SH – 13), Hence, this marginal increase in the traffic,

will not affect the road infrastructure of the study area.





CHAPTER 5. Environment Management Plan

5.1. Introduction

Prediction of the potential adverse environmental and social impacts arising from

development interventions is at the technical heart of EIA process. An equally

essential element of this process is to develop measures to eliminate, offset, or

reduce impacts to acceptable levels during implementation and operation of projects.

The integration of such measures into project implementation and operation is supported by clearly defining the environmental requirements within an Environmental

Management Plan (EMP).

Normally, potential impacts are identified early during the initiation of project, and measures to avoid or minimize impacts are incorporated into the alternatives being

considered. In this respect, some of the most important measures to protect the

environment and local communities become integral to the project design, and may

not be reflected in a formal EMP.

For the proposed expansion of IOCLP, by way of EIA study propose to identify all the likely potential impacts, collect data information and incorporate all the measures necessary to avoid or minimize impacts on surrounding environment due to proposed

expansion unit. Many of the mitigation measures are already taken up in the

engineering design itself.

5.2. Objectives of EMP

Overall objective of EMP:

Prevention: Measures aimed at impeding the occurrence of negative environmental

impacts and/or preventing such an occurrence having harmful environmental impacts.

Preservation: Preventing any future actions that might adversely affect an

environmental resource or attribute.

Minimization: Limiting or reducing the degree, extent, magnitude, or duration of

adverse impacts.

5.3. Components of EMP

EMP for IOLCP to set up manufacturing unit of APIs intermediates considers the

following aspects:

Description of mitigation measures

Description of monitoring program

Institutional arrangements

Implementation schedule and reporting procedures

Institutional framework includes the responsibilities for environmental management as

well as responsibilities for implementing environmental measures.

5.4. Air Environment

Construction Phase:

Excavators shall be used for construction. The excavated material shall be stacked at

safe places for backfill at a later stage of construction.

To control the fugitive emission during construction phase adequate water sprinkling system will be developed



Operation Phase (Fugitive Dust):

Handling & transportation of the raw material as per norms.

Sprinkling of water to control fugitive dust emission.

Speed of vehicles inside the factory premises will be controlled.

Greenbelt will be maintained to attenuate the air pollution.

Closed loop system will be adopted to reduce the workers exposure to hazardous

chemicals during manufacturing process.

Proper personal protective equipment will be provided to the workers.

All trucks will be transported after covering from the top.

Raw material unloading will be done by mechanized truck unloading system.

Dust collectors will be in line with unloading hoppers.

Material handling in the plant will be done in closed conveyors.

All the trucks being used for transportation of raw material and final product shall be

checked for "Pollution under Control" certificate prior to their entry to the plant

premises.

5.4.1. Air Pollution Control Measures

Measures for Reducing Stack Emissions

In the proposed project, DG set will be used only during the power failure and will

relate to a separate stack. ESP with stack height of 60 mtr shall be installed for

dispersion of particulate matter from Boiler. All process vents will be routed through

dedicated two stage scrubbing system.

The recovery and recycling of solvents in the process is a key issue in achieving

productivity and an edge in competitive world. Hence, all the solvent mixtures

generated from different stages of the products will be fractionated in a state-of-the-

art solvent recovery system to give 95-98% recovery depending upon composition of

solvent mixtures and their boiling point. Chilled brine will be used in condensers to

recover the solvents.

Similarly, all the reaction vessels (six streams) will be connected with the individual

scrubbing system so that any toxic fumes and vapors generated during reaction get

neutralized. The scrubber stack will meet existing norms emission. IOLCP also

ensure that for the expansion unit there is no leakage occurs from various stage of

process equipments (equipment flanges, pumps, drains, sample points etc.) to pollute

the working area.

Measures for Fugitive Emissions

The fugitive emissions of organic chemicals and VOCs may come from leakage

through valves, fittings, pumps, etc. Though this is not expected to be significant, it

may be reduced further by adopting the following measures:

LDAR system should be strictly followed.

All process drains/ equipment washing should be collected in closed pit (to avoid fouling of work area through odour etc.) and taken to ETP.

Regular maintenance of valves, pumps and other equipment to prevent leakage and

thus minimizing the fugitive emissions of VOCs.



Regular monitoring of VOCs shall be conducted in the areas prone to fugitive

emissions.

The monitoring at working environment shall be carried out and shall be recorded in

the prescribed form of the Factories Act.

The operation of centrifuging/ filter will be done in closed equipment to avoid any

vapours coming out in the local atmosphere. The vents of centrifuges / filters will be

connected to scrubbers. The drying of the product is done in a closed type

continuous Fluidized Bed dryer/ Nudge filter to avoid the exposure of any chemicals

to human being. Volatile organic solvents are carefully handled in a closed system,

thereby preventing any discharge of these chemicals into the air.

Adequate systems shall be provided to capture the odour /emissions from process

plants & maintain the emission quality as per recommended guidelines with central

scrubber having caustic solution, before venting it in to the atmosphere

The design features as suggested in Table 5.1 for new equipment may be

considered.

Table 5.1 : Design Features for Minimization of Fugitive Emissions

S. No. Equipment Design Features Control Efficiency, %

1 Pumps Seal less design 100

Dual Mechanical Seal 100

2 Valves Seal less Design 100

3 Compressor Dual Mechanical Seal 100

4 Connectors Weld together 100

5 Pressure Relief Devices Rupture Disc 100

6 Sampling Connection Closed loop sampling 100

Table 5.2 : Ambient air environment impact and management plan

S.No. Env.

Elements

Stages and Source Impact Area Management Plan

1. Air

Environment

Construction Phase:

Construction activity

is limited may caused

by emission of dust

such as the

movements of

vehicles, speed, soil

stripping, excavation,

back filling and

reinstatement

Within Plant

boundary

Sprinkling water on

excavated earth

material.

Operational Phase:

Truck Movements

Within Plant

boundary

Truck mounted

vacuum cleaning

system



Process emission Emission with

in NAAQMS

Standards

within study

area

Adequate pollution

control equipment

provided

5.5. Fly ash Management

Utilization of ash produced by Boiler as a thrust area of its activities and all possible actions will be taken to enhance level of ash utilization. In the boilers, various avenues for ash utilization will be explored as delineated in the above sections. Fly ash generated from boiler has been sent to low lying areas with consent of village panchayat and as per PPCB conditions.

• IOLCP will make efforts to motivate and encourage entrepreneurs to set up units for manufacture of ash-based products such as fly ash bricks, lightweight aggregates, cellular concrete products etc as ancillary industries in the region.

• IOLCP would request State Government to make mandatory to utilize ash/ash-based products in Works Department and other Government/State sponsored projects to enhance ash utilization;

The ash will be utilized in various construction materials to the maximum extent and 100% utilization will be achieved. All efforts will be made for maximum utilization of ash. IOLCP is committed to explore possibilities for ash utilization considering new technologies and avenues and try to achieve the target fixed by MoEF in this regard. IOLCP shall committed to comply with the Fly Ash Utilization Notification, 1999 and as amended thereof.


Construction Phase

Noise will be generated due to operation of heavy equipment and increased

frequency of vehicular traffic in the area. However, these impacts will be short

term and intermittent in nature. The noise effect on the nearest inhabitants

during the construction activity will be negligible, as the noise levels will be

dissipated within the existing plant area itself. Nevertheless, the following

mitigation measures shall be adopted:

The on-site workers shall be made to use noise protection devices like ear muffs/ ear plugs;

The construction equipment shall be maintained and serviced regularly such that the equipment-based noise standards are maintained as per the design specifications; and

Further, no worker shall be allowed to expose to more than 90 dB (A) in an 8-hour shift and under no circumstances the noise level from any equipment shall be greater than 115 dB (A).

Operation phase:

All the design/installation precautions as specified by the manufacturers with

respect to noise control shall be strictly adhered to;

High noise generating sources shall be insulated adequately by providing suitable enclosures;



Design and layout of building to minimize transmission of noise, segregation of particular items of plant and to avoid reverberant areas;

Acoustic design of building;

The noise control system will be designed to form an integral part of the plant;

Other than the regular maintenance of the various equipment, ear plugs/muffs are recommended for the personnel working close to the noise generating units;

All the openings like covers, partitions shall be designed properly; and

Inlet and outlet mufflers shall be provided which are easy to design and construct.

The green belt in and around the plant periphery will attenuate the noise level.

Table 5.3 : Ambient noise environment impact and management plan



S.NO Components Stages and sources Impact Zone Management Plan

1. Noise Environment

During Construction Phase:

Movement of heavy equipments

Within Plant Boundary

Regular maintenance of the construction equipments.

Provision of protective devices like ear muff/plugs to the workers.

During Operation Phase:

Increase in ambient Noise level from equipments, pump DG sets and compressors. However incremental level is insignificant due to provision of acoustic enclosures for noise generation sources.

Provision of rubber padding/ noise isolators

Provision of silencers to modulate the noise generated by machines

Provision of protective devices like ear muff/plugs to the workers.

Greenbelt development in and around the plant periphery

5.7. Water Environment

5.7.1. Construction Phase:

The water environment is susceptible to change during construction because

of the effluents from sanitary facilities for the construction workers, washing of

vehicles and spillage of fuels. Following mitigation measures shall be

adopted:

Suitable treatment measures already place at construction site for the

expansion project;

The vehicle maintenance area shall be in such a manner as to prevent

contamination of surface and ground water sources by accidental spillage

of oil;



The washing effluents from the vehicle maintenance area are likely to

contain suspended solids and oil & grease. Hence, an oil trap followed by

settling tank shall be provided for the treatment of these effluents; and

The waste oil collected in the oil trap shall be sold to authorized re-

refiners for off-site recycling.

Sanitation

The construction site shall be provided with enough and suitable toilet facilities for

workers to meet the proper standards of hygiene. Existing ETP have been used

during construction phase.

Operation Phase:

All the process effluent generated from the proposed project will be treated in

ETP & recycled back in the process and Treated water will be send for greenbelt

development. Domestic effluent which will be treated in existing ETP. No impact

on ground or surface water is envisaged due to the project. However, rainwater

harvesting and recycle & reuse of all the industrial effluent have been adopted in

the project to conserve the water resources.

Table 5.4 : Water environment impact and management plan

S.NO Components Expected Impact Impact

Zone

Management Plan

1. Water

Environment

During Construction Phase:

Water will be needed mainly

for construction and

domestic purpose i.e. for

drinking and sanitation

Within

Plan

Boundary

Domestic waste

water sends to

ETP/STP

During Operation Phase:

Generation of high TDS and

High COD effluent. Follow

Zero Discharge concepts

Generation of Low TDS and

Low COD effluent

High TDS and

High COD effluent

sent to MEE follow

with ATFD.

Low TDS and Low

COD treated in

ETP & and treated

water use for

greenbelt with in

premises.

No waste water

Discharge outside

the boundary

Domestic waste

water sends to

ETP/STP.



5.7.2. Strom water management

Storm water collected through storm drains will be stored and reused Saving of even

small drop of water can make considerable saving in wider spectrum over a period &

is also be helpful in creating awareness for water conservation amongst people. It

also improves our input water quality.

5.8. Biological Environment

Ecological base line surveys in the core and buffer zones, reveals no exceptional

features of wildlife interest. The survey based on following criteria.

Table: Ecological criteria & Observations

Land use Being an existing unit, the land use of site is already under industrial. No tree cutting is required.

The land within 10 km radius of the site is under agriculture or settlements. No sensitive ecosystem including forests are present within 10 km area of the project site.

Diversity Species diversity of flora as well as fauna species is restricted to agro ecosystem.

Rarity There is no endemic, rare or threatened species in site as well as in study area.

Proximity There are no Biosphere Reserve, National Park, Wildlife Sanctuary, present within 10 km area of the site

Potential value After developing a wide and dense greenbelt in plant area will increase habitat condition especially for avifauna.

Based on the ecological baseline study following mitigation measures have been

suggested:

Regeneration / restoration of rare plants and animals: No rare plants and wildlife

species exists in the core and buffer zone, hence protection and conservation plan is

not required.

Improvement of biodiversity: Environment management cell of the project

proponent will look after the day to day environment monitoring requirement and

Greenbelt development in and around the project site.

5.9. Green Belt development plan

In order to mitigate and minimize the environmental impacts, arising due to project

especially from air pollution, noise pollution, soil erosion etc. the Greenbelt

development in the area delineated can provide the best mitigation option. The green

canopy not only absorbs some of these pollutants as carbon sink but also improves

the aesthetic environment, besides attenuating the noise levels.



Being an existing unit dense greenbelt havin 10-15 m width has been already

developed all around the plant premises except few places. Beside boundary

plantation there are there 10 patches in which mixed plantation has been done by

IOLCP. Greenbelt is already developed in 30 acres (more than 33%) of the land. The

photographs of the existing greenery are given below:

Photographs of the existing Greenbelt

It has been proposed by IOLCP that additional 9000 trees shall be planted in the area

of existing eucalyptus plantation which shall be replaced with native species

plantation like gulmohar, shisham, siris, jamun, Kadam, daikan, neem, kaner etc. for

this plantation IOLCP has earmarked a budget of Rs. 30 lakhs including maintenance

cost for 5 year.

Beside this maintenance of the existing greenbelt shall be done on regular basis for

which IOL Chemical has already kept a budget for Rs. 20 lakhs as a capital cost.

IOLCP has planted approx. 26000 tree/shrubs and herbs in existing greenbelt. The

tree species like Eucalyptus, neem, Daikan, sadabahar, Ficus spp., jamun, Champa,



kadam gulmohar along with shrubs and herbs has been planted under existing

greenbelt.

5.10. Land Environment

Construction phase

Following materials shall be stored and handled carefully under applicable safety guidelines.

Some of the precautions of storage include the following:

Dyke enclosures shall be provided;

Diesel and other fuels shall be stored in separate storage tanks with dyke enclosures;

PPE and Fire extinguisher/tenders will be provided.

Site Security

Adequate security arrangement shall be made to ensure that the local inhabitants and the

stray cattle are not exposed to the potential hazards of construction activities. Availability of

boundary wall shall be helpful in meeting this objective.

Operation phase

Hazardous waste will be disposed as mentioned in the Chapter 2.

There will be no major source of hazardous waste generation due to the proposed

project that would be causing harm to the environment, as major solid waste is

gypsum which will be sold to cement industries and hazardous wastes are ETP

Sludge & used oil which will be disposed as per Hazardous Waste (Management,

Handling & Transboundary Movement) Rules, 2016 and its amendments.



Hazardous wastes will be stored at earmarked area with impervious flooring and with shed to

eliminate chances of contamination of land and ground water.

Following measures will be implemented.

Maintain records of hazardous waste generation and disposal as per HWM rules

2016.

Ensure all necessary precautions are taken during handling, loading and unloading of

hazardous wastes.

Ensure training to persons involved in handling/ transportation of hazardous

chemicals/ wastes.

Ensure availability of MSDS of hazardous materials, whenever required.

Ensure required PPE’s are provided to the persons involved in handling/

transportation of hazardous chemicals/ wastes

Table 5.5 : Impact and management plan

S.NO Components Stages and Sources Impact Zone Management Plan

1. Land

Environment

During Construction

Phase:

Soil Excavation

Within plant

boundary

Top soil generated

from various

activities like

excavation etc. will

be stored and

preserved to use in

greenbelt

development.

During Operation

Phase:

Solid waste disposal and

Hazardous waste

generation storage.

Hazardous waste

shall be disposed

off as per HWM

rules 2016.

Periodic monitoring

shall be carried out.

Zero liquid

discharge will be

maintained.

5.11. Resource Conservation/ Waste Minimization

For the proposed expansion project IOLCP has proposed to take adequate resource

conservation measures in the proposed plant. K ey measures taken for natural

resource and energy conservation are as given below:-

Used oil will be stored in covered storages / hard flooring to prevent any

contamination in soil/ ground water.

Proper scheduling of preventive maintenance of critical machines will

minimize used oil generation.

Energy efficient drives / LED lights to be used.

Reduction of lighting power consumption by optimum use of electrical

lights in plants by installing timers.



Use of variable frequency drive in plant.

Enough care will be taken to prevent/minimize energy losses at each

stage.

Period Energy audit will be done.

Zero liquid discharge will be maintained for reduction in fresh water

consumption.

Also use of Energy Efficient Lighting, Transformers, HVAC system, Use of

Energy Efficient Motors, electrical appliances to minimize the energy

consumption in addition to Process Planning.

5.11.1. Strategy of Energy conservation in IOLCP

IOLCP have separate process engineering team of chemical engineers as Energy

conservation cell led by certified energy auditor from BEE (Team leader is a company

employee), they are identifying the scope for energy saving, if any of the area is

evaluated as potential source for energy saving, then the entire team, process the

thought in multi dimensions and verified by using software like CHEMCAD & ASPEN.

Once the thought is implemented successfully then the same thought is implemented

across the locations and systems to get full benefit of each idea generated.

IOLCP have strict monitoring of latent heat used and its recovery, which in-turn going

back to cooling tower may be directly or indirectly. In this process IOLCP gets three

dimensional benefits (1- Efficient use of energy generated, 2- Process productivity

improved without adding any new equipment, 3- Energy is re-circulated before

discard to reduce operating cost for treatment.

IOLCP have an eye on advanced techniques which can give benefits in product

quality with minimum resource utilization. Based on technical evaluation and

comparison of quality, productivity, energy, human and environment, this process of

evaluation and implementation gives immense confidence in proposed change which

can improve the contribution.

IOLCP have a focus to use continuous processing techniques instead of batch

processing and explore the possibility to convert batch processing to continuous

processing so that wastage of time and energy can be minimized, and end product

becomes cost effective to the end user.

IOLCP have stringent control on equipment and their MOC selection, priority given to

the most energy efficient / effective equipment / MOC to get optimal output.

IOLCP have stringent control on the usage of water which again gives three

dimensional benefits apart from EHS norms / quality, 1- Less energy consumption in

water generation, 2- Less load on ETP thus less energy is required to treat the

effluent generated, 3- Opportunity to enhance the productivity in the same set of

equipments by increasing the flow / batch sizes.

Utility system is all decentralized with minimum heat losses during transit and least

power consumption, this gives immense benefit to the optimal control on the process

and emergencies.



Energy consumption norms per unit production for all products manufactured in the

organization are monitored and compared with the targeted value by the MIS division

and reported to top management on daily basis, which directly impacts the product

cost and generates the scope for further improvement initiatives.

Figure 5.1 National Energy Conservation Award - 2016

5.12. Facilities for Employees

Existing unit already provide suitable facility to the employees. For the proposed

expansion company will give preference to local people (Skilled People) for

employment. Unit is more concern for the safety and health of its people, including the

larger community outside of the company and the environment. All employees will be

trained to work on sites in the safest possible manner and shall be made aware of the

consequences of unsafe act. After expansion company will also provide the shelter,

safe drinking water, sanitation facility. Specific budget is used for current employee,

Company is planning to allocate adequate budget after expansion for safety and

Occupational health management of the employees.

5.13. IOLCP HSE Policy



Figure 5.2 : HSE Policy

5.14. Environment Management Cell

Environment Management Cell made to Maintain EHS policy. Environment

Management Cell works for regular monitoring of the environment. Structure of

Environment Management Cell is given below.

S.No Post / Designation No of Persons

1 President 1

2 Assistant Manager ( Environment ) 1

3 Officer 1

4 Operator 5

5 Helper 3



Responsibilities of Environment Management Cell (EMC)

EMC undertake regular monitoring of the environment and do audit of the

environmental performance. It also co-ordinate with local authorities to see that

all environmental measures are well coordinated.

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.

Suitably responding to emergency situations.

Controlling activities inside the project, until the environmental problem has been

corrected.

Ambient Air Monitoring done every Month in different locations of plant Area

Effluent Quality: Daily/Every Week in own laboratory; Quarterly from PPCB

approved laboratory and Water pollution Trends.

Hazardous Waste Analysis and took steps to reduce/recycle Hazardous Waste

Stack Emissions: Every Quarter.

President

1 No

Asst Manager (Environment

Division)

1 No

Officer

1 No

Operator

5 Nos

Helper

3 Nos



Time to time soil testing

Internal audit to check environmental performance

To meet compliance of SPCB/CPCB/MoEF and other departments

Trainings to Employees to control Pollution.

Suitably responding to emergency situations.

To coordinate/Liaison with government authorities and regulatory bodies for

timely submission of compliances like Form-3, On line SPM Analyzer readings,

Hazardous Waste Stock, CCTV camera recording, Ground Water abstraction ,

Form –IV, Form-V and six monthly compliance to MoEF.

Monthly review meeting of the Environmental Management System and the

assessment of progress made to address pending issues from the previous review

meeting.

Setting of new Environmental objectives.

To detection of deficiencies in the applied system.

To find out problems in the Environmental Management System.

Changes / amendments in the legislation, which may affect and/or modify the

Plant’s Environmental Management System policy.

Responsible for follow up of the decisions taken and for keeping the relevant

records.



5.14.1. Post – Operational Monitoring Program

IOLCP will carry out environment monitoring for existing and proposed expansion as

per monitoring plan proposed as follows:

Discipline Location Parameter Frequency

Remarks

Meteorology One Temp. {max.; min.};

Relative humidity; Rain fall; Wind speed and

direction.

Daily Being complied

Ambient Air Quality

Four Ambient air monitoring of parameters specified by RSPCB in their air consent from time to time within plant

Once a Month

Parameters as

applicable /as per

products being manufactured

Stack Emission All continuous stacks

Emission monitoring of

process/flue gas stacks

set as given in air consent from time to time

Quarterly

Parameters as

applicable /as per


Effluents Final effluents discharge point

--- Once a

day.

Parameters as

applicable /as per


Ground Water

Quality (two

piezometric

wells)

two piezometric wells within plant premises

Parameters are essential parameters as per IS

10500:2012.

Half yearly (before monsoon and after monsoon)

Parameters as

applicable /as per


Noise Plant area &periphery

Day & Night time noise level

Monthly

Soil Plant area pH, conductivity, sulphate, calcium and

magnesium etc.

Once a year

Health Check Up

All Plant Personnel

Diseases related to chemical unit

Annually

5.14.2. Budget for environmental management plan



The environmental Budget proposed for the project is mention below.

Table 5.6 : Budget for environmental management plan

Particulars

Proposed EMP Cost

(Rs. in Lacs) Capital

Proposed EMP Cost

(Rs. in Lacs/annu

m) Recurring

Basis for cost estimates

Air pollution control &Noise Pollution Monitoring

95 20

Air pollution controlling equipment’s,

Monitoring of Air Environment, Ambient noise monitoring, acoustic hoods / enclosures, noise mapping, hearing protection

Water Pollution control

410 406.25

Capital cost would include cost of ETP and STP including Civil work, mechanical work, and electrical work and piping work is included. Recurring cost is cost of treatment of waste water at site

Solid and hazardous waste management

25 15.25

Capital cost would include cost of providing storage space for hazardous waste. Recurring cost would include cost of transportation & disposal

Environment monitoring and management

75 20

The recurring cost would be incurred

on hiring of consultants and payment

of various statutory fees to regulatory agencies.

Occupational Health

65 20 Periodic Health checkup, PPEs etc

Green belt & Rainwater Harvesting

20 1.5

Capital cost would include cost of plant species and labor cost and recurring cost would include cost of maintenance of that green belt including cost of required water for plant growth

Total 690 483



CHAPTER 6. RISK ASSESSMENT& DISASTER MANAGEMENT PLAN

6.1. Introduction

Industrial plants deal with materials, which are generally hazardous in nature by virtue of

their intrinsic chemical properties or their operating temperatures or pressures or a

combination of these. Fire, explosion, toxic release or combinations of these are the hazards

associated with industrial plants using hazardous chemicals. More comprehensive,

systematic and sophisticated methods of Safety Engineering, such as, Hazard Analysis and

Quantitative Risk Assessment have now been developed to improve upon the integrity,

reliability and safety of industrial plants.

The primary emphasis in safety engineering is to reduce risk to human life, property and

environment. Some of the more important methods used to achieve this are:

Quantitative Risk Analysis: Provides a relative measure of the

likelihood and severity of various possible hazardous events by

critically examining the plant process and design.

Work Safety Analysis: The technique discerns whether the plant

layout and operating procedures in practice have any inherent

infirmities.

Safety Audit: Takes a careful look at plant operating conditions, work

practices and work environments to detect unsafe conditions.

Together, these three broad tools attempt to minimize the chances of accidents occurring.

Yet, there always exists, no matter how remote, probability of occurrence of a major

accident. If the accident involves highly hazardous chemicals in sufficiently large quantities,

the consequences may be serious to the plant, to surrounding areas and the populations

residing therein.

6.2. Risk Assessment

A three ‗levels‘ risk assessment approach has been adopted for them/s IOL Chemicals &

Pharmaceuticals Limited (hence forth IOLCP) proposed expansion project to be set up at

Village Fatehgarh Channa on Mansa Road, Tehsil & District Barnala Punjab. The risk

assessment levels are generally consistent with the practices encountered through various

assignments for medium and large chemical complexes. The brief outline of the three-tier

approach is given below:

Level 1 – Risk Screening

This is top-down review of worst- case potential hazards/risks, aimed primarily at identifying

plant sites or areas within plant, which pose the highest risk. Various screening factors

considered include:

Inventory of hazardous materials;

Hazardous Materials properties;

Storage conditions (e.g. temperature and pressure);

Location sensitivity (distance to residential areas / populace).

The data / information is obtained from plant. The results provide a relative indication of the

extent of hazards and potential for risk exposure.

Level 2 – Major Risk Survey (Semi - Quantitative)



The survey approach combines the site inspection with established risk assessment

techniques applied both qualitative as well quantitative mode. The primary objective is to

identify and select major risks at a specific location in the plant considering possible soft

spots / weak links during operation / maintenance. Aspects covered in the risk usually

include:

Process Hazards;

Process Safety Management Systems;

Fire Protection and Emergency response equipment and

programs.

Security Vulnerability;

Impact of hazards consequences (equipment damage, business

interruption, injury, fatalities);

Qualitative risk identification of scenarios involving hazardous

materials;

Risk reduction measures.

Selection of critical scenarios and their potential of damage provide means of prioritising

mitigative measures and allocate the resources to the areas with highest risks.

Level 3 – Quantitative Risk Assessment (Deterministic)

This is the stage of assessment of risks associated with all credible hazards (scenarios) with

potential to cause an undesirable outcome such as human injury, fatality or destruction of

property. The four basic elements include:

i. Hazards identification utilizing formal approach (Level 2, HAZOP

etc.);

ii. Frequency Analysis. Based on past safety data (incidents /

accidents); Identifying likely pathway of failures and quantifying

the toxic / inflammable material release;

iii. Hazards analysis to quantify the consequences of various

hazards scenarios (fire, explosion, BLEVE, toxic vapor release

etc.). Establish minimum value for damage (e.g. IDLH, over

pressure, radiation flux) to assess the impact on environment.

iv. Risk Quantification: Quantitative techniques are used considering

effect / impact due to weather data, population data, and

frequency of occurrences and likely hood of ignition / toxic

release. Data are analyzed considering likely damage (in terms of

injury / fatality, property damage) each scenario is likely to cause.

QRA provides a means to determine the relative significance of several undesired events,

allowing analyst and the team to focus their risk reduction efforts where they will be beneficial

most.

IOLCP shall manufacture pharmaceutical chemicals at the proposed site.Table2.4 inChapter

2 gives the list of raw materials. Solid raw materials are stored in ware house while liquid and

gaseous raw materials are stored in tank farms and covered area. The list of bulk liquid

storages of raw materials is as given below:



Table 6.1. Liquid/Gaseous Bulk Storages

S.No Raw Material State Storage

Total Capacity In MT

Nos. of Tanks & Tanks Cap. In KL[p1]

1 Acetic Acid Liquid 552 tank-1 249 Tank-2 275 Tank-3 29

2 Ethyl Alcohol Liquid 4050 Tank-1 1900 Tank-2 1900 Tank-3 250

3 Iso Butyl Benzene Liquid 526 Tank1 280 tank-2 150 tank-3 26 Tank-4 35 Tank-5 35

4 Acetyl Chloride Liquid 120 Tank-1-40, Tank-2 40, Tank-3 40

5 Iso Propyl Alcohol Liquid 46 Tank-1 31 Tank-2 15

6 Sulphuric Acid Liquid 115 Tank-1 25 Tank-2 75 Tank-3 15

7 Acetic Anhydride Liquid 525 Tank-1 248, Tank-2 277

8 Chlorine Gas In Cylinders store in chlorine

yard

164 No. of Tonner cylinders

9 Toluene Liquid 260 Tank-1 260

10 Propylene Gas 180 Bullet 3 151 m3 each

11 Chloroform Liquid 20 Tank-1 20

12 Acetone Liquid 55 Tank-1 16 Tank-2 13 Tank-3 15 Tank-4 15

13 Methanol Liquid 35 Tank-1 24 Tank-2 15

14 Hydrochloric Acid Liquid 50 Tank-1 50

15 Hexane Liquid 95 Tank-1 30 Tank-2 30 Tank-3 15 Tank-4 20

16 Hydrogen gas Gas In cylinders 7m3 and 10 m3

17 Cyclohexanone Liquid 10 Tank-1 10 KL

18 Methylcyanoacetate Liquid 10 Tank-1 10 KL

19 Cyclohexane Liquid 10 Tank-1 10 KL

20 Dry HCl Gas In Cylinders, Stored in

Chlorine Yard

50 Kg Cylinder

21 Methylethylketone Liquid 20 Tank-1, 20 KL

22 Di chloro methane Liquid 20 Tank-1, 20 KL

23 Ethyl acetate Liquid 1265 tank1 264 tank-2 121 tank-3 264 Tank-4 514 Tank-5 20 Tank-6 20 Tank-7 30

https://mail.iolcp.com/owa/owa#_msocom_1





Tank-8 30

24 Propanol Liquid 40 Tank-1,40 KL

25 Ammonia Gas in Cylinders 120 Nos

6.3. Risk Screening Approach

Proposed Plant: Risk screening of IOLCP proposed project was undertaken through data /

information provided by IOLCP. Data of major / bulk storages of raw materials and other

chemicals were collected. MSDS of hazardous chemicals were studied vis a vis their

inventories and mode of storage. IOLCP plant will be using number of hazardous chemicals

and producing chemicals /pharmaceutical products– some of them hazardous in nature. The

chemicals stored in bulk (liquid or gaseous) and defined under MSHIC Rule will be

considered for detailed analysis.

Hazardous materials have been defined under MSIHC Rules (1989) - 2 (e) which means.

0. (i) Any chemical which satisfies any of the criteria laid down in Part I of

Schedule I and is listed in Column 2 of Part II of this Schedule;

Toxic Chemicals: Chemicals having the following values of acute toxicity

and which owing to their physical and chemical properties, can produce

major accident hazards:

S. No Toxicity Oral Toxicity

LD50 (mg/kg)

Dermal

Toxicity LD50

(mg/kg)

Inhalation

Toxicity LC50

(mg/l)

1 Extremely Toxic >5 < 40 < 0.5

2 Highly Toxic >5 – 50 > 20 – 200 < 0.5 – 2.0

3 Toxic >50 - 200 > 200 - 1000 > 2 – 10

Flammable chemicals:

Flammable gases gases which at 20oC and at standard pressure of

101.3KPa are:-

Ignitable when in a mixture of 13% or less by volume with air, or;

Have a flammable range with air of at least 12% points regardless

of the lower flammable limits.

(i) Extremely flammable liquids: chemicals which have a flash point lower than

or equal to 230C and the boiling point less than 350C;

(ii) Very Highly flammable liquids: chemicals which have a flash point lower

than or equal to 230C and the boiling point higher than 35 0C;

(iii) Highly Flammable Liquid: Chemicals, which have a flash point lower

than or equal to 60 0C but higher than 23 0C.

(iv) Flammable liquids: chemicals, which have a flash point higher than 60 0C but lower than 90 0C.

Explosives: Explosive means a solid or liquid or pyrotechnics substance (or a mixture of

substances) or an article.



a) Which is capable by chemical reaction of producing gas at such a temperature and

pressure and at such a speed as to cause damage to surroundings;

b) Which is designed to produce an effect by heat, light, sound, gas or smoke or a

combination of these as the result of non-detonative self-sustaining exothermic

chemical reaction.

I. any chemical listed in Column 2 of Schedule 2;

II. any chemical listed in Column 2 of Schedule 3;



Table 6.2. Hazardous Analysis Raw materials stored in Bulk

S

No

Material S. No & Threshold Quantity (TQ in Kg) as

per MSHIC Rules

Chemicals Hazards Potential Remarks

Schedule-

1, Part-II

Schedule-2,

Part-I

Schedule-3,

Part-I

Hazards Toxic

DT->---mg/Kg;

OT----mg/Kg;

IT----mg/l;

(Rats)

Acetic Acid

C2-H4-O2

CAS No:64-19-7

Clear colorless Liquid with pungent vinegar

like odor

2 - FP-12 0C ; BP-64.70C

LEL-6%; UEL- 36%

Incompatibilities with

Other Materials:

Oxidizing agents,

reducing agents, acids,

alkali metals,

potassium, sodium,

metals as powders (

DT->--- 1060

mg/Kg (Rabbit);

OT----3310

mg/Kg (Rat);

IT----5620 ppm; 1

hr

(Mouse)

May be fatal or

cause blindness if

swallowed. Vapor

harmful.

Flammable liquid

and

vapor. Harmful if

swallowed,

inhaled, or

absorbed through

the skin. Causes

eye, skin, and

respiratory tract

irritation. May

cause central

nervous system

depression.

Ethyl Alcohols (Ethanol)

C2H6O

CAS No; 64-17-5

A clear colorless liquid with pleasant odor

248 --- --- Colorless liquid

Flammable: FP- 16.6

0C; Causes respiratory

tract irritation. May

cause liver, kidney and

heart damage. Causes

DT->--- 15800

mg/Kg (Rabbit);

OT----10,470

mg/Kg (Rat);

IT----30000 mg/l

(Rat)



moderate skin / eye

irritation. On ingestion

may cause

gastrointestinal tract

irritation, vomiting and

diarrhea.

Iso Butyl Benzene

CAS No:538-93-2

Flammable Colorless liquid with sweet odor

BP: 171 0C

--- --- --- Flammable liquid and

vapor

May be fatal if

swallowed and enters

airways

Causes skin irritation

Causes serious eye

irritation

DT->--- 2000

mg/Kg (Rat);

OT----mg/Kg;

IT----mg/l;

(Rats)

Acetyl Chloride

CH3COCl

CAS No: 75-36-5

Flammable fuming liquid with strong odour

BP:52 0C

--- --- --- Very hazardous in

case of eye contact

(irritant), of ingestion,

of inhalation.

mouth and respiratory

tract. Skin contact may

produce burns.

DT->---mg/Kg;

OT---- 910

mg/Kg;

IT----mg/l;

(Rats)

Isopropyl Alcohols

CAS No: 67-63-0

334 --- --- Flash Pt: 55.00 F

Method Used: TCC

Explosive Limits: LEL:

2.5% UEL: 12.1%

LD 50/ LC 50: Acute

dermal Rabbit 1300

mg/kg; Acute

inhalation Rat (8

hours) 12000 ppm.

Sulphur Acid CAS No: 7664-93-9 UN No: 591 --- --- Flammability: Will not ERPG-1: 2.0



1830 burn Health Hazard:

Extremely hazardous -

use full protection;

Reactivity: Violent

chemical change

possible

mg/m3

ERPG-2: 10

mg/m3

ERPG-3: 30

mg/m3

IDLH: 15 mg/m3

Acetic anhydride

CAS No: 108-24-7

UN No: 1715

A clear colorless liquid with a strong odor of

vinegar.

3 --- --- Flammable;

Dangerous when

exposed to heat or fire;

Irritating vapors are

generated when

heated; Health

Hazards: Liquid is

volatile and causes

little irritation on

uncovered skin.

However, causes

severe burns when

clothing is wet with the

chemical or if it enters

gloves or shoes.

Causes skin and eye

burns and irritation of

respiratory tract.

Nausea and vomiting

may develop after

exposure. Acetic

Anhydride reacts

violently on contact

with water, steam,

methanol, ethanol,

ERPG-1: 0.5

ppm-

ERPG-2:15 ppm

ERPG-3: 100

ppm

IDLH: 200 ppm



glycerol and boric acid.

Reaction with water is

particularly dangerous

in presence with

mineral acids (e.g.,

nitric, perchloric,

chromic, sulfuric acid)

Chlorine

CAS No:7782-50-5

UN No:1017

A greenish yellow gas with a pungent

suffocating odor. Toxic by inhalation.

119 5

TQ-1: 10MT

TQ-2: 25

MT

108

TQ-1: 10MT

TQ-2: 25 MT

(Gas); Non-

Combustible; May

ignite other

combustible materials

(wood, paper, oil, etc.).

Mixture with fuels may

cause explosion.

Health Hazards:

Poisonous; may be

fatal if inhaled. Contact

may cause burns to

skin and eyes.

Bronchitis or chronic

lung conditions

ERPG-1: 1.0 ppm

ERPG-2: 3.0 ppm

ERPG-3: 20 ppm

IDLH: 10 ppm

Toluene CAS No: 108-88-3 UN No:

1294

628 --- --- A clear colorless liquid

with a characteristic

aromatic odor. Flash

point 40°F

Flammability: Ignites at

normal temperatures;

Vapor is heavier than

air and may travel a

considerable distance

to a source of ignition

ERPG-1: 50 ppm

ERPG-2: 300

ppm

ERPG-3: 1000

ppm

IDLH: 500 ppm

Health Hazard

Vapors irritate

eyes and upper

respiratory tract;

cause dizziness,

headache,

respiratory arrest.

Liquid irritates

eyes and causes

drying of skin. If



and flash back; aspirated, causes

coughing,. If

ingested causes

vomiting, griping,

diarrhea,

depressed

respiration.

Refinery Grade Propylene

CAS No: 115-07-1

Colorless Gas (Liquid under pressure)

Odor: Mild Olefin

Vapor Density: 1.4 (air=1)

--- 6

TQ-1: 50

MT

TQ-2: 300

MT

1

TQ-1: 15 MT

TQ-2: 200

MT

F P: -108°C

LEL: 2.0%

UEL: 11.1%

Flammable Gas

Unusual Fire and

Explosion Hazards:

Vapors are heavier

than air and may travel

along the ground or

may be moved by

ventilation and ignited

by flame, sparks,

heaters or other

ignition sources at

distant locations.

Vapors may explode if

ignited in a closed

area. Containers may

explode in a fire.

NFPA 704 (1997)

Health: 1

Flammability: 4

Reactivity: 1

Chloroform

(Trichloro methane)

[CHCl3]

CAS No: 67-66-3

UN No: UN1880

130 --- --- Toxic by inhalation.

Irritating to respiratory

system. Exposure to

decomposition

products

STEL: 2 ppm 60

minutes.

STEL: 9.78

mg/m3 60

minutes.



Colorless liquid; Pleasant Ethereal odor

BP-60.5 0C

may cause a health

hazard. Serious effects

may be delayed

following exposure.

Toxic if swallowed.

Aspiration hazard if

swallowed. Can enter

lungs and cause

damage.

Irritating to skin.

LD50 (rat)- 894

mg/Kg

Acetone

[C3 H6 O]

CAS No: 67-64-1

Colorless liquid; Pleasant Ethereal odor

BP-56.2 0C

4 -- -- Hazardous in case of

skin contact (irritant),

of eye contact (irritant),

of ingestion, of

inhalation. Slightly

hazardous in case of

skin contact

(permeator).

Flammable: Limits-

Lower-2.6%; Upper-

12.8%

ORAL (LD50):

Acute: 5800

mg/kg [Rat].

VAPOR (LC50):

Acute: 50100

mg/m 8 hours

[Rat].

Methanol

CAS No:67-56-1

UN No:1230

377 --- --- A colorless volatile

liquid with a faintly

sweet pungent odor

like that of ethyl

alcohol.

Highly Flammable;

Behavior in Fire:

Containers may

explode.

ERPG-1: 200

ppm

ERPG-2: 1000

ppm

ERPG-3: 5000

ppm

IDLH: 6000 ppm

Health Hazards:

Exposure to

excessive vapor

causes eye

irritation, head-

ache, fatigue and

drowsiness.

50,000 ppm will

probably cause

death in 1 to 2



hrs. Swallowing

may cause death

or eye damage.

Hydrochloric acid (Gas) CAS No:

7647-01-0 UN No: 1789

313 --- --- Not Flammable;

Inhalation of fumes

results in coughing and

choking sensation, and

irritation of nose and

lungs. Liquid causes

burns

ERPG-1: 3.0 ppm

ERPG-2: 20 ppm

ERPG-3: 150

ppm

IDLH: ---- ppm

Plant uses liquid

and emits HCl gas

n-Hexane

CAS No:110-54-3

UN No:1208

306 --- --- Clear colorless liquids

with a petrol -like odor.

Flash points -9°F

Highly flammable;

Vapors may explode;

TEEL-1: 400 ppm

TEEL-2: 3300

ppm

TEEL-3: 8600

ppm

IDLH 1100 ppm

Health Hazards:

Inhalation causes

irritation of

respiratory tract,

cough, mild

depression,

arrhythmias.

Aspiration causes

severe lung

irritation,

coughing,

pulmonary

edema;

Hydrogen

247 --- --- Hazardous in case of

ingestion, of inhalation.

Slightly hazardous in

case of skin contact

(irritant, permeator), of

eye contact

(irritant).

ORAL (LD50):

Acute: 5620

mg/kg [Rat]. 4100

mg/kg [Mouse].

4935 mg/kg

[Rabbit]. VAPOR

(LC50): Acute:

45000 mg/m 3 -3

Highly

Flammable/

Explosive



hours [Mouse].

16000 ppm 6

hours [Rat].

Cyclohexanone

C6H10O

CAS No:108-94-1

Oily Liquid with acetone like odor BP:155.6

0C

162 --- --- Flammable;

Hazardous in case of




(irritant, permeator).

OT (LD50):

Acute: 1516

mg/kg [Rat]. DT

(LD50)

948 mg/kg

[Rabbit].

MethylcyanoacetateC4H5NO2

CAS No:105-34-0

Clear colorless liquid BP: 204—207 0C

--- --- --- No Data available No Data available

Cyclo Hexane

CAS No: 110-82-7

Liquid. With:

Chloroform-like odor;

LFL: 1.3%

UFL:8.4%

BP: 80.70C

FP: -18 0C

161 --- --- Slightly hazardous in



eye contact (irritant), of

ingestion, of inhalation

ORAL (LD50):

Acute: 12705

mg/kg [Rat]. 813

mg/kg [Mouse].

DERMAL

(LD): Acute:

>18000 mg/kg

[Rabbit].

Flammable

Methylethylketone

C4H8O

CAS No:78-93-3

Liquid with Pleasant Sweetish odor

BP:79.6 0C

--- --- --- Hazardous in case of

skin contact (irritant,

permeator), of eye

contact (irritant), of

ingestion, of inhalation

(lung irritant).

OT(LD50): Acute:

2737 mg/kg [Rat].

DT (LD50) 6480

mg/kg [Rabbit].

(LC50): 23500

mg/M3 8 hours

[Rat].

Di chloro methane

C-H2-Cl2

CAS No:75-09-2


case of eye contact

(irritant), of ingestion,

DT->---mg/Kg;

OT----1600

mg/Kg;



Liquid BP:39.75 0C of inhalation.

Hazardous in case

of skin contact (irritant,

permeator).

Inflammation of the

eye is characterized by

redness, watering, and

itching.

IT----mg/l;

(Rats)

Ethyl acetate

(C4 H8 O2)

CAS No:141-78-6

Flammable Colorless liquid; Pleasant

Ethereal odor

247 --- --- Hazardous in case of





eye contact

(LD50): Acute:

5620 mg/kg [Rat].

4100 mg/kg

[Mouse].

(LC50): 16000

ppm 6 hours

[Rat].

Propanol

CH3CH2CH2OH

CAS NO:71-23-8

Flammable liquid with alcohol like odor


case of eye contact

(irritant). Hazardous in



ingestion, of

inhalation.

Inflammation of the

eye is characterized by

redness, watering, and

itching.

DT->---4060

mg/Kg (Rabbit);

OT----1870

mg/Kg;

IT----67882.3

ppm;

(Rats)

Ammonia 31 2

TQ-1: 60

MT

TQ-2: 600

MT

105

TQ-1: 50 MT

TQ-2: 500

MT

Fire Hazards: (Gas);

Mixing of ammonia

with several chemicals

can cause fire

hazards, / or

ERPG-1: 25 ppm

ERPG-2: 150

ppm

IDLH: 300 ppm

Contact with liquid

may cause frost

bite.



explosions; vapors are

toxic- irritation to eyes

and respiratory tract.

TQ-I: Threshold quantity (for application of rules 4,5,7 to 9 and 13 to 15) TQ-II: Threshold quantity (for application of rules 10 to 12)

1. Note:

1. Oral Toxicity (OT) in LD50 (mg/kg)

2. Dermal Toxicity (DT) in LD50 (mg/kg)

3. Inhalation Toxicity in LC50 (mg/l) [4 hrs.]



IOLCP is using 122 raw materials (Table 2.4). Out of 122 raw materials 59 are solids (being

stored in bags / drums), 37 are liquids (being stored in drums), 22 are liquids being stored in

tanks and four are gases being stored in cylinders and bullet (Propylene.)

Hazards analysis has been carried out for gaseous raw materials and liquid raw materials

stored in bulk (tanks). Six raw materials are having not been mentioned in MSIHC Schedule

1Part II (List of Hazardous and Toxic Chemicals). Three gaseous raw materials namely

Chlorine, Ammonia and Propylene have been mentioned in MSIHC List both in Schedule 1

Part II and Schedule 2. Other raw materials have been mentioned in Schedule 1 Part II only.

6.4. Hazardous Materials Storage

The solid raw materials will be received in bags or drums and will be stored in chemicals go-

downs. The products (liquid or solid) will be packed in drums and stored in product go-downs

as per market demand. The bulk storages of liquid hazardous materials are given in the

Table 6.1.

The solid materials powder or granules spillage can result in polluting small area only. The

damage to personnel can be through ingress- dermal (if individual come in contact), oral (if

individual food gets infected through fugitive dust) or inhalation (fugitive dust). The main

route is fugitive dust which in covered area will move to short distance only. Some of the raw

materials are though stored in bulk (quantity) but in drums only.

The pharmaceutical product will be both as liquid and solid. The product storage for liquid will

be in drums and ISO containers and for solid in bags depending upon client requirement.

The risk is through liquid and gaseous materials (Chlorine/Ammonia/HCL (Toxic) and

Propylene (Thermal/explosion)), which are volatile/gaseous material (toxic) and

inflammable/explosive materials. The toxic vapours due to spillage of such material can

travel to some distance (as they are stored in covered go-downs) and cause damage.

6.5. QRA Approach

Identification of hazards and likely scenarios (based on Level-1 and Level-2 activities) calls

for detailed analysis of each scenario for potential of damage, impact area (may vary with

weather conditions / wind direction) and safety system in place. Subsequently each incident

is classified according to relative risk classifications provided in Table below as Table 6.3:

Table 6.3. Risk Classification

Stage Description

High

(> 10-2/yr.)

A failure which could reasonably be expected to occur within the

expected life time of the plant.

Examples of high failure likelihood are process leaks or single instrument

or valve failures or a human error which could result in releases of

hazardous materials.

Moderate

(10-2 --10-

4/yr.)

A failure or sequence of failures which has a low probability of

occurrence within the expected lifetime of the plant.

Examples of moderate likelihood are dual instrument or valve failures,

combination of instrument failures and human errors, or single failures of

small process lines or fittings.

Low A failure or series of failures which have a very low probability of

occurrence within the expected lifetime of plant.



Stage Description

(<10-4) Examples of ‗low‘ likelihood are multiple instruments or valve failures or

multiple human errors, or single spontaneous failures of tanks or process

vessels.

Minor

Incidents

Impact limited to the local area of the event with potent for ‗knock – on-

events‘

Serious

Incident

One that could cause:

Any serious injury or fatality on/off site;

Property damage of $ 1 million offsite or $ 5 million onsite.

Extensive

Incident

One that is five or more times worse than a serious incident.

Assigning a relative risk to each scenario provides a means of prioritising associated risk

mitigation measures and planned actions.

6.6. Thermal Hazards

To understand the damages produced by various scenarios, it is appropriate to understand

the physiological/physical effects of thermal radiation intensities. The thermal radiation due to

tank fire usually results in burn on the human body. Furthermore, inanimate objects like

equipment, piping, cables, etc. may also be affected and need to be evaluated for damages.

Table 6.4, Table 6.5and Table 6.6(below), respectively give tolerable intensities of various

objects and desirable escape time for thermal radiation.

Thermal hazards could be from fires or explosion. Fire releases energy slowly while

explosion release energy very rapidly (typically in micro seconds). Explosion is rapid

combustion of gases resulting in rapidly moving shock wave. Explosion can be confined

(within a vessel or building) or unconfined (due to release of flammable gases).

BLEVE (boiling liquid expanding vapour explosion) occurs if a vessel containing a liquid at a

temperature above its atmospheric boiling point ruptures. The subsequent BLEVE is the

vaporisation and subsequent explosion of large fraction of its vapour contents; possibly

followed by combustion or explosion of the vaporised cloud if it is in combustible range.

Thermal hazards have been considered for various scenarios including:

Fire in inflammable chemicals storage tanks.

Table 6.4. Effects due to Incident Radiation Intensity

Incident Radiation

kW/m2 Damage Type

0.7 Equivalent to Solar Radiation

1.6 No discomfort on long duration

4.0 Sufficient to cause pain within 20 sec. Blistering of

skin (first degree burn is likely).

9.5 Pain threshold reached after 8 sec. Second degree

burn after 20 sec.

12.5 Minimum energy required for piloted ignition of wood,

melting of plastic tubing etc.



25

Minimum Energy required for piloted ignition of wood,

melting, plastic tubing etc.

37.5 Enough to cause damage to process equipment.

62.0 Spontaneous ignition of wood.

Table 6.5. Thermal Radiation Impact to Human

Exposure

Duration

Radiation Energy {1%

lethality; kW/m2}

Radiation Energy

for 2nd degree

burns; kW/m2

Radiation Energy

for 1st degree

burns; kW/m2

10 sec 21.2 16 12.5

30 9.3 7.0 4.0

Table 6.6. Tolerable Intensities for Various Objects

Sl. No Objects Tolerable Intensities

(kw/m2)

1 Drenched Tank 38

2 Special Buildings (No window, fire proof

doors)

25

3 Normal Buildings 14

4 Vegetation 10-12

5 Escape Route 6 (up to 30 sec.)

6 Personnel in Emergencies 3 (up to 30 sec.)

7 Plastic Cables 2

8 Stationary Personnel 1.5

1.1. Damage due to Explosion

The explosion of a dust or gas (either as a deflagration or detonation) results in a reaction

front moving outwards from the ignition source preceded by a shock wave or pressure front.

After the combustible material is consumed the reaction front terminates but the pressure

wave continues its outward movement. Blast damage is based on the determination of the

peak overpressure resulting from the pressure wave impacting on the object or structure.

As a safety measure IOLCP is storing highly hazardous raw materials in isolated places with

full safety measures. Damage estimates based on overpressure are given in Table 6.7below:

Table 6.7. Damage due to Overpressure

Sl. No Overpressure

(psig / bar)

Damage

1. 0.04 Loud Noise / sonic boom glass failure



2. 0.15 Typical pressure for glass failure

3. 0.5 - 1 Large and small windows usually shattered

4. 0.7 Minor damage to house structure

5. 1 Partial demolition of houses made

uninhabitable.

6. 2.3 Lower limit of serious structure damage

7. 5 – 7 Nearly complete destruction of houses

8. 9 Loaded train box wagons demolished

9. 10 Probable destruction of houses

10. 200 Limits of crater lip

In IOLCP case explosion are likely due to Propylene and other inflammable chemicals.

6.7. Toxic Release

Hazardous materials handled and stored in bulk in IOLCP complex are toxic gases i.e.

Chlorine, Ammonia and HCl and liquids (as detailed in Table 6.1). Some of these chemicals

are stored in bulk (in tank farm).

Damage criteria: For toxic release the damage criteria considered is IDLH concentration. In

the absence of non-availability of IDLH, ‗Inhalation Toxicity (IT) data for rats‘ are considered.

‗IT‘ data are used for the products as IDLH are not available for these chemicals.

6.8. Data Limitations

It is also observed that very little data or information (regarding physical properties required

for modelling in case of dilute chemicals is available about the chemicals. In such cases pure

chemicals are considered for modelling.

6.9. Likely Failure Scenarios

Few likely failure scenarios have been selected after critical appraisal of raw materials and

storage inventories. Failure scenarios selected are as given in Table 6.8 below:

Table 6.8. Different Failure Scenarios

S. No. Scenario Remark

RM-1 Acetic Acid Toxic

RM-2 Chlorine Toxic

RM-3 Propylene (Gas) Thermal

RM-4 Hexane Thermal

RM-5 Hydrogen Thermal

RM-6 Cyclohexane Toxic

RM-7 Ethyl Acetate Toxic

RM-8 Ammonia Toxic

RM-9 HCl Gas Toxic

6.10. Weather Effect



The effect of ambient conditions on the impact of fire / heat radiation and GLC of hazardous /

toxic material can be beneficial as well as harmful. A high wind (turbulence) can dilute the

toxic material while stable environment can extend the reach of IDLH or IT (inhalation LC50

rats for products) concentration to long distance. Any inflammable gas / vapour release in

turbulent weather will soon dilute the hazardous gases below LEL and thus save the

disaster.

6.11. Incidents Impacts

The identified failure scenarios (Table 6.8) have been analysed (Using ALOHA and EFFECT

Modules) for the impact zones considering damage due to thermal and toxic impacts. Each

incident will have Impact on the surrounding environment which in extreme case may cross

plant boundary. The impact zones for various scenarios are given in Table 6.9.

Table 6.9. : Hazards Scenario Impact

Scenario

No.

Scenario Impact Zone

(m)

Remarks

Scenario Raw Material

RM-1 Acetic Acid

Heavy Leakage

85 IDLH; Stability Class D; Template-

1

RM-2 Chlorine

Leakage

473

306

IDLH; Stability Class D; Template-

2

Stability Class F; Template-3

RM-3 Propylene

(Gas)

Fire

Heavy

Spillage-

Heavy

Spillage

48

208

50

1st Degree Burn; Template-4

Flammable area of Vapor Cloud;

Template 5

Vapor Cloud Explosion; Serious

injury impact zone;Template-6

RM-4 Hexane

Spillage & Fire

14 1st Degree Burn; Template-7

RM-5 Hydrogen Pipe

Line Leakage &

Fire

<10 1st Degree Burn

RM-6 Cyclohexane

Spillage; Toxic

Impact Zone

<10 IDLH; Stability Class D

RM-7 Ethyl Acetate



Scenario

No.

Scenario Impact Zone

(m)

Remarks

Scenario Raw Material

Heavy Spillage

Toxic

Impact

Zone

Burning

Puddle

17

26

IDLH; Stability Class D

1st Degree Burn; Template-8

RM-8 Ammonia

Leakage; Toxic

Impact Zone


9

RM-9 HCL Gas

Leakage; Toxic

Impact Zone


10

Templates of Scenario

2.

3.

Template 1. Heavy Acetic Acid Spillage-Toxic Impact Zone (Stability Class D)



Template 2. Chlorine pipe leakage: Toxic Impact Zone Stability Class ―D‖

Template 3. Chlorine pipe leakage: Toxic Impact Zone Stability Class ―F‖



Template 4. Propylene Leakage& Fire—Likely Thermal Impact

Template 5. Propylene Heavy Leakage—Flammable area of Vapour Cloud



Template 6. Propylene Heavy Leakage— Overpressure (blast force) from

vapor cloud explosion

Template 7. Hexane Leakage & Fire —Thermal Impact Zone



Template 8. Ethyl Acetate heavy Leakage & Fire —Thermal Impact Zone

Template 9. Heavy Ammonia Leakage-Toxic Impact Zone; Stability Class ―D‖



Template 10. Heavy HCl Leakage-Toxic Impact Zone; Stability Class ―D‖

6.12. Consequential Impacts

The consequential impacts from each incident scenario can be though thermal, over

pressure wave and toxic route. The damage can be on plant personnel (and neighbouring

residents in case incident crosses boundary), property and loss in production.

6.13. Thermal and Explosion Hazards

Incidents involving thermal hazards are mainly due to raw material fire (due to spillage). The

impact (1st degree burn) is limited to 48~ m (Propylene spillage &fire) and ~ 26 m (Heavy

Ethyl Acetate spillage & Fire case) only (i.e. within plant boundary). However, in case of

heavy propylene spillage and evaporation the flammable/ explosive vapour cloud can move

the consequences can go to worse. The consequences can also go worst in case of domino

effect to other tanks.

6.14. Toxic Hazards

Toxic hazards are mainly due to Chlorine /Ammonia /HCl gases and other toxic chemicals

leakage and its impact can cross the plant boundary (if not controlled in time). The impact

due to Chlorine can go up to 473 m i.e. it may cross the plant boundary limit and affect larger

area / nearby populace depending upon wind direction. Toxic impacts due to HCl gas, Acetic

acid and Ammonia leakage can go up to 88m, 85m and 38 m respectively.

IOLCP is using Chlorine/ Ammonia/HCl gas/Propylene gas as basic raw material and shall

provide following emergency safety measures:

Caustic/ neutralisation pit shall be provided adjoining for Chlorine storage and

HCl gas storage for any emergency.

Alternatively, hood shall be if covers the Chlorine/ Ammonia/ HCl cylinders in

emergency and necessary connections provided directly connecting to the

neutralization system.



Spray more quantity of water /fog to suppress the air born vapours or to avoid

the formation of vapor cloud of ammonia gas, because ammonia vapor cloud

may explode vigorously at its LEL and convert in to flash fire.

Emergency kit and two sets of breathing apparatus provided to meet any

emergency.

4. Water sprinkler system provided for propylene gas bullet to handle any

leakage.

6.15. Other Hazards

The other hazards in the plant include (but not limited to):

Other toxic hazards due to acids / other toxic spillages (mainly limited to

spillage area only.).

Mechanical hazards due to machines / equipment.

Hazards due to individual soft spots like walking casually and noticing a pit

and falling or colliding/ stumbling or slipping (not noticing a wet place etc.).

6.16. Other Toxic Hazards

Other hazardous chemicals including products their impact will be limited to spillage area.

The acid spillage if comes in contact with metal parts will produce hydrogen which is highly

flammable gas. Any person moving in area and getting splash will get the injury. In addition,

the spillage will cause pollution problem. The spillage is to be collected and neutralized for

toxic contents before disposal.

6.17. General Control Measures

Since some of the substances in use at IOLCP are hazardous with fire potential and also

toxic in nature, it is necessary to use appropriate control measures recommended for such

substances:

6.18. Flammable Gas Fires

Fire control generally consists of directing, diluting and dispersing the inflammable gas/vapor

to prevent contact with persons, to prevent it from infiltrating structures if the leak is out door,

and to avoid its contact with ignition sources while, if possible, simultaneously stopping the

flow of gas. Water in the form of spray, applied from hoses or monitor nozzles or by fixed

water spray system cools the burning vapours / gas.

6.19. Process Safety System to be Developed at IOLCP

Process & Plant Safety:

Conducting Preliminary Safety Analysis (A1), Basic Safety Review (A2), Detailed Safety

Review (A3), Pre-Start-Up Safety Review (A4) & Pre Start-Up Safety audit according to PPS

(Process & Plant Safety) directive (details mentioned in following flow diagram)

Every change in the process, procedure, equipment, etc. will be done through robust

management of change (MOC) procedure

Pre-Start up Safety Reviews for all modification

Pressure testing of pipelines and replacement of fragile pipelines and tanks by

prevention project

Hazardous area classification

Internal safety rounds for P&PS

Control P&IDs, and Lock opened (LO)/ Lock closed (LC) procedures are in place

TOPPS (Top Performance in Process & Plant Safety) training to all employees

Root Cause Analysis of all incidents



Pre-Start up Safety Reviews for all modification

Occupational Safety:

Permit to Work procedure and Monthly monitoring of all filled permit for continual

improvement

Mobilized Near- Miss Reporting and award scheme

HSE rounds: PMT (Plant Management Team) of one plant takes HSE round of

another plant. Exchange of best practices among plants

MSDS Management

Tool Box talk with contractors

Central Safety Committee

Departmental Safety Committees

HSE Coordinator and Monitor program: Shop floor employees‘ participation in Safety

activities

Celebration of theme-based Safety days/ weeks at site

Safety Induction program for new joiners (both company & contract employees)

Emergency Preparedness:

On-Site Emergency Plan for the site

Training on On-Site Emergency Action Plan

Regular Site level Mock drills and Plant specific Fire Drills and Leak, spill drills

Availability of First aiders, Fire Fighters and Rescue members in each shift

Maintenance of Fire hydrant system, sprinkler system and portable fire extinguishers

Periodic testing of fire hydrant and sprinkler systems

Three Fire Tenders and Two Ambulances

Occupational Health:

Pre-employment & Annual Medical Examination

Quarterly/Periodical Physical Examinations

Canteen Employees Examination

Fork lift operators Examination

Recall services & Follow-Up

Return to work assessment

Exit Examination

Training on Counselling, Hearing Conservation Program, Hazardous Chemical

Awareness Program, Shop floor training, First-aid (138Nos. Certified First Aiders),

etc.

Legal records: All medical records of employees to be maintained.

Emergency Medical services: Ambulance services, First-aid boxes, Decontamination

facility etc.

Health Promotional Activities: Awareness on Medical issues, Ergonomics awareness

programs, Stress management, De-addiction program, etc.

6.20. Safety System for Toxic Material Handling

Following precaution Taken while handling Toxic materials

Highly Toxic chemical is stored in storage room with lock and key.

Inventory records are maintained.

Toxic material is stored in well ventilation and out of sunlight

It is stored away from incompatible chemicals.

Keeping containers tightly & securely closed when not in use

Toxic chemical charging is done inside the closed room in presence of shift in-charge.



Local Ventilation system is provided to avoid exposure at work place.

Vent gas is passing through scrubber system for absorption & reduction of pollution.

Standby pump provision is available for LEV & scrubber system.

Decontamination facility is provided

Safety PPE‘s is providing during charging.

Breathing air provision is provided at toxic chemical handling area.

Training to employees is providing for manual handling of toxic chemicals.

First aid training also provided to concern employees.

Antitoxic kit is maintaining inside OHC.

First aid kit provision is available at work place area.

Eye wash/Safety shower stations are readily available nearby and are tested

regularly

To avoid fire and explosion nitrogen blanketing, earthing & bonding, electrical flame

proof equipment‘s, pressure rated equipment‘ are provided.

Suitable fire extinguisher and spill cleanup equipment are maintained.

Dyke provision is available where liquid toxic chemicals are stored.

Appropriate spill control equipment and procedures is available.

MSDS is maintained inside the concern plant / department.

Precautionary placard is displayed nearby the work place.

Toxic chemicals sign board is displayed on container.

Avoiding any welding, cutting, soldering or other hot work on an empty container of

toxic chemicals.

Good housekeeping is maintaining.

Toxic gas detector also provided at workplace.

Toxic chemical waste is collecting in separate pit and transferring to ETP for its

treatment.

Always ensuring that the waste container used is compatible with the waste material

Ensuring that the waste container is properly and accurately labelled.

Unauthorized person entry is restricted.

Restricted for eating, drinking & smoking at work place.

Employees are trained for emergency of toxic chemicals.

Toxic chemical spill, leak drills are conducting for awareness, preparedness &

response during an emergency.

Work place area monitoring is to be carried out for ensuring exposure at workplace.

Process is performed in closed conditions.

Regular pressure testing for pipelines and equipment to ensure tightness

6.21. WORKPLACE MONITORING PLAN

Work zone monitoring is carried out by HSE department every month for gaseous

pollutants and dusts. Records are to be kept in standard Form as per Factories Rules.

Location for samplings shall be identified. Samples are analyzed for Air borne

concentration of hazardous chemicals in ppm.

The analyzed results are compared with the threshold limit values (TLV) of

international organizations. The monitoring program is based on the Action level

Concentration (ALC) which is 50% of the TLV. If the analyzed concentration is < ALC,

no regular monitoring is required, only occasional checks (once in a year) to ensure

the acceptability of the system.

If the analyzed concentration is > ALC < TLV then the monitoring is carried out at

regular interval (once in two months). Incase analyzed concentration is > TLV then



corrective actions are decided by Plant Manager, General Manager - works and

Engineering Manager and they are implemented. After implementation again,

monitoring is carried out.

The sampling for gaseous pollutants and air pollutants are done by Air sampling

pump. A sample report of work area monitoring is attached as Annexure V.

6.22. Arrangement for ensuring health and safety of workers engaged

in handling of toxic materials

All persons working in manufacturing units are surveyed by regular medical

examinations.

Pre-employment Medical examination to be carried out for all employees prior to

employment at well-known multispecialty hospital.

Checkups & tests carried out as per Factory rules / SPCB guidelines.

6.23. Safety Recommendations

6.23.1. Commonly Recommended Control Measures

A number of preventive control measures for hazardous occurrences have been analysed

and discussed above. Some more salient points are enumerated below:

All storage tanks in the tank farm should be dyke. Other operation and

maintenance features shall be based on established best safety

practices.

Concentration detectors for hazardous chemical vapors (e.g.

Chlorine/Ammonia/HCl/VOC and other chemicals etc.) fire Smoke /

heat detectors and fire alarm should be installed at all strategic

locations in the plant.

A schedule for preventive maintenance including health survey of all

plant equipment should be adhered to as far as possible.

Ensure the absence of ignition sources in storage area.

Ensure placement of firefighting facilities, such as, carbon dioxide, dry

chemical powder and foam type fire extinguishers in addition to fire

hydrant system, at strategic locations. Spill control measures, such as,

removal of all ignition sources from the spill area and ventilating the

area as well as soaking the spilled material with paper, towel or mud

and letting the volatile substance evaporate slowly in a safe area.

Compulsory use of protective clothing, non-sparking tools and warning

signs during critical operations and maintenance.

Training / refresher courses on safety information‘s / norms.

Eyewash and showers should be put up at strategic places for use

during emergencies.

A group of plant personnel should be trained in first aid, rescue, firefighting and emergency

control measures (IOLCP has trained team of Fire fighters, Rescue Team, First Aid trained

team). These personnel will form core group/emergency squad who will fight the emergency

and act as rescue and first aid team.



To ensure communication from isolated places/locations Walkie-Talkie be made available to

persons working in these areas. This will considerably improve the effectiveness of

emergency management.

There is no substitute for training-mock drills and these must be held at regular interval

keeping the following objectives in mind:

Real time mock-drill should be carried out for probable/likely hazardous situation (after the

plant is successfully commissioned).

Target to be set up for various tasks and events during an emergency.

Weak links should be marked, and corrective action taken to improve effectiveness during

emergency.

IOLCP team already understand the implication and hazards in Chemical & Pharmaceutical

industry and has implemented most of the measures in the existing plant.

6.23.2. Occupational Health and Safety

Occupational Health and Safety (OHS) are of prime importance more so in hazardous

industries. Industries have various types of hazards and QRA is carried out to understand the

hazards potential from various incidents. Pre-emptive steps can be planned to safeguard

from likely causes. Some of the

Frequent causes of accidents

Fire and explosion: explosives, flammable material

Hazards from Toxic Materials

Mechanical Hazards such as:

Being struck by falling objects

Caught in between machine parts

Snapping of cables, ropes, chains, slings

Handling heavy objects

Electricity Hazards

o Electrocution

o Short circuits and consequential fire.

o Poor illumination etc.

Other Hazards:

Falls from height inside industrial units or on the ground

Struck by moving objects; Slipping on wet surfaces

Sharp objects

Oxygen deficiency in confined spaces; Lack of personal protective equipment (PPE),

housekeeping practices, safety signs

Consequential hazards due to extreme Temperatures;

Consequential hazards due to vibration

Consequential hazards due to radiation;

Many more hazards.

Hazardous substances and wastes

Heavy and toxic metals

Lack of hazard communication (storage, labeling, material safety data

sheets)

Batteries, fire-fighting liquids

Welding fumes



Volatile organic compounds (solvents)

Inhalation in confined and enclosed spaces

Ergonomic and psychosocial hazards

Many of the hazards are as result of working environment.

Repetitive strain injuries, awkward postures, repetitive and monotonous work,

excessive workload

Long working hours, shift work, night work, temporary employment (Long

working hours, shift work, night work, temporary employment, Mental stress,

human relations) which results in less attention at work place and

consequential incidents and accidents.

Lack of education and training / awareness is another prime cause of

accidents.

Considering above, QRA analysis and the nature of activities at IOLCP the following

steps for OHS activities have been suggested:

Response to Injuries: Based on a survey of possible injuries, a procedure for response to

injuries or exposure to hazardous substances should be established. All staff should have

minimum training to such response and the procedure ought to include the following:

Immediate first aid, such as eye splashing, cleansing of wounds and skin, and

Bandage etc.

Immediate reporting to a responsible designated person

If possible, retention of the item and details of its source for identification of possible

hazards.

Medical surveillance

Recording of the incident

Investigation, determination and implementation of remedial action

6.23.3. Transportation:

Class A petroleum products (equivalent raw materials) will be received through road

tanker and stored in underground storage tank as per petroleum Act & Rules.

Road tanker unloading procedure will be in place and will be implemented for safe

unloading of road tanker.

Static earthing provision will be made for tanker unloading.

Earthed Flexible Steel hose will be used for solvent unloading from the road tanker.

Fixed pipelines with pumps will be provided for solvent transfer up to Day

tanks/reactors.

Double mechanical seal type pumps will be installed.

NRV provision will be made on all pump discharge line.



Table 6.10. : Transportation, Unloading and Handling safety Measures

SR.NO. ACTIVITY TYPE OF POSSIBLE

HAZARD

MITIGATION MEASURES

1 Transportation of Chemicals like

Chlorine, Ammonia, Propylene

and acids& Solvents by road

tanker

Leakage& Spillage

Fire,& explosion,

Toxic release

• Check the source of leakage point.

• Do not touch damaged containers or spilled material unless wearing

appropriate protective clothing.

• Stop leak if you can do it without risk.

• Use water spray to reduce vapors; do not put water directly on leak,

spill area or inside container.

• Keep combustibles (wood, paper, oil, etc.) away from spilled

material.

• Isolate the area

• Isolate the container

• Training will be provided to driver and cleaner regarding the safe

driving, hazard of Flammable chemicals, emergency handling.

• TREM card will be kept with TL.

• Fire extinguishers will be kept with TL.

• Flame arrestor will be provided to TL exhaust.

• Instructions will be given not to stop road tanker in populated area.

• Clear Hazard Identification symbol and emergency telephone

number will be displayed as per HAZCHEM CODE.

• Appropriate PPEs will be kept with TL.

2 Acids and Solvents Road tanker

unloading at project site.

Leakage& Spillage







Fire, & explosion,

Toxic release




material.




• Spray the water on leakage

• Priority will be given to Tanker to immediately enter the storage

premises at site and will not be kept waiting near the gate or the main

road.

• Security person will check License, TREM CARD, Fire extinguisher

condition; Antidote Kit, required PPEs as per SOP laid down.

• Store officer will take sample as per sampling SOP from sampling

point.

• After approval of QC department unloading procedure will be allowed

be started.

Following precautions will be adopted during unloading

• Wheel stopper will be provided to TL at unloading platform.

• Static earthing will be provided to road tanker.

• Tanker unloading procedure will be followed according to check list

and implemented.

• Flexible SS hose connection will be done at TL outlet line.

• The quantity remaining in the hose pipeline will be drained to a small

underground storage tank, which will be subsequently transferred by



nitrogen pressure to the main storage tank thus ensuring complete

closed conditions for transfer from road tanker.

• All TL valves will be closed in TL.

• Only day time unloading will be permitted.

3 Chlorine, fuels and acid&

Solvents Storage tank safety

Leakage& Spillage,

Fire, Explosion

Toxic release.








material.




• Spray the water on leakage

• SS storage tank will be provided as per IS code.

• Dyke wall will be provided to storage tank.

• Level transmitter will be provided with low-level high level auto cut-off

provision.

• Vent will be connected to water trap and vent of water trap will be

provided with flame arrestor.

• Water sprinkler system will be provided to storage tank.

• Fire hydrant monitor with foam attachment facility will be provided.

• Dumping / Drain vessel/alternate vessel will be provided to collect

dyke wall spillage material.



• FLP type pump will be provided.

• Nitrogen blanketing will be provided to storage tank.

• Double static earthing will be provided to storage tank.

Double Jumper clip will be provided to all Solvent handling pipeline

flanges.

4 Transportation of Chemicals

transfer from Day tank to

reactor.

Leakage, Spillage due

to Line rupture, Flange

Gasket failure, Fire,

Explosion, Toxic

release.

• Gravity transfer.

• Total quantity of day tank material will be charged in to reactor at a

time.

• Static earthing will be provided to storage tank.

• Double Jumpers will be provided to pipeline flanges.

EIA/EMP Report for expansion of APIs and Bulk drug production unit by IOLCP


6.24. Emergency facilities

Emergency Management Planning (EMP) should be developed considering the likely hazards in the

plant and sincerely implemented. Mock drills for various scenarios should be carried out and results of

the drills should be recorded. Weal links in the mock drills should be strengthened.

Objectives

The Emergency Management Plan (EMP) is developed to make the best possible use of the resources

available at IOLCP and the nearby agencies to provide help/assistance in case of an emergency in the

plant. The activities will include:

Rescue the victims and give them the necessary medical attention in the shortest

possible time.

Safeguard another person (evacuate them to a safer place).

Contain the incident and control it with minimum damage to human and life and

property.

Provide necessary information to families/relatives of affected persons, outside

agencies including media and statutory bodies.

6.25. Emergency Management Plan [EMP]

IOLCP is storing two Hazardous Chemicals (Chlorine and Propylene) more than Threshold limit

as mentioned in MSIHC rules and as such has prepared EMP and submit it to Statutory

Authorities. IOLCP is regularly carrying out Mock drills to check the effectiveness of the EMP.

6.26. Conclusion & Recommendations

The hazard analysis and risk assessment of few possible selected incident scenarios indicates that such

incidents mostly are not limited to plant battery limits and have impact on adjoining plants. There are

possibilities of domino effect and the secondary scenario not predictable can be worse than the primary

one. One scenario (specifically toxic hazards scenario-Chlorine) is crossing the IOLCP plant boundaries.

The direction of impact will be in down wind direction (wind direction and speed vary with season).

Chlorine and Propylene detectors are already installed at site for safety measures.



CHAPTER 7. SUMMARY AND CONCLUSION

M/s IOL Chemicals & Pharmaceuticals Limited (IOLCP) is based at Village Fatehgarh Channa

on Mansa Road, Tehsil & District Barnala Punjab. It is spread over 62 acres.

IOLCP is proposing for expansion of existing unit by addition some new products and increasing

the capacity of existing product. Hence applied in MOEF&CC and received TOR on 1th June

2018 (Letter No. J-11011/976/2008-IA-II(I)) for proposes expansion of existing products and

addition of new products from the capacity of 543.45 TPD to 671.95 TPD at its existing location

(Village Fatehgarh Channa, Mansa Road District Barnala – 148101, Punjab) The total

investment is ~ Rs 205 crores. The capital investment towards environment management is

estimated to be Rs.690 lacs and recurring cost will be Rs. 483 lacs.

Connectivity:

The proposed site is at about 1.45km, SE from village Fatehgarh Channa, State Highway 13 is

at a distance of .81 km NW in Direction. Nearest Railway station is Barnala railway station 8.69

km from the project site and Chandigarh airport is approx. 130 km away in NE direction from

project site (aerial distance). No National Parks, Wildlife Sanctuaries, Tiger/ Elephant Reserves,

Wildlife Corridors etc. falls within 10 km radius from the plant site.

Project Description:


hence the capacity increases from 543.45 TPD to 671.95TPD for the manufacturing of bulk drug

and API drugs production unit. IOLCP has applied for TOR in 19 April 2018 and Standard TOR

has been issued on 1st June 2018.

Description of Environment:

Primary baseline data has been collected as per the TOR prescribed by MOEF during 15th March 2018 to 15th June 2018 for one complete season Baseline Data was generated by following the standard procedures of the Ministry of Environment & Forests and the Central Pollution Control Board.

Air Environment: Ambient air quality was monitored at eight locations in the study area. The locations were selected as per CPCB guidelines The mean concentration of PM2.5 in all location ranges between 42 to 48 µg/m3.. The mean concentration of PM10 in all location ranges between 85 to 93 µg/m3 This may be due to the dust generated from thrashing of Wheat crop in the agricultural field, presence of industries in addition to plying of heavy traffic such as trucks and other combustion engine vehicles in nearby roads. SO2 level in all the location ranges between 6.2-20.5 µg/m3, NOx level in all the location ranges between 14.0-41.2 µg/m3, which was found well within National Ambient Air Quality standards i.e. NAAQMS (80µg/m3). The NH3 level in all monitoring locations ranges between 9 to 0.23 µg/m3. The NH3 level in all monitoring location is under permissible limit i.e. NAAQMS 400 µg /m³. The 8 hrs. CO level in all monitoring locations ranges between 0.14 to 0.81 mg/m³.



Noise Environment:The ambient noise level of all the monitoring locations were found well

within the National Ambient Noise Quality Standards prescribed for industrial (Standards - 75

dBA during day time and 70 dBA during night time) residential area (Standards - 55 dBA during

day time and 45 dBA during night time) and commercial area (Standards - 65 dBA during day

time and 55 dBA during night time) The Ambient noise are well within the limit as per prescribe

standard.

Water Quality: Six surface water samples and eight groundwater samples were collected from

the area for chemical and biological analysis. Overall the ground water quality of the study area

is found well within the permissible limits. No metallic and bacterial contaminations were

observed in ground water samples.



upstream and downstream point of the project site high bacterial contamination were observed in

Nala water quality meeting the BDU criteria Class D which is fit for propagation of wildlife and

fisheries.

Canal Water quality: The canal water quality is good for Drinking water source after conventional

treatment and disinfection and meeting the class C of Best designated uses of CPCB.

Pond Water Quality: Bacterial contamination were observed in pond water samples. Dissolve

oxygen is found within the range while BOD was found slightly on slightly high than the Class C

of Best designated uses. Hence the pond water is fit for Propagation of Wild life and Fisheries

and meeting the criteria D of Best designated uses of CPCB.

Soil Quality: The soil quality of study area is sandy loam. The pH and conductivity of the soil is

within acceptable range. The soil analysis describes that the soil of the study area is moderately

fertile.

Sensitive Ecosystem: There are no environmentally sensitive components such as National

Park, Wildlife Sanctuary, Elephant / Tiger Reserve, migratory routes of fauna and wet land

present within 10 Km radius of plant site.

Socio economic environment: As per Census of India- 2011, Barnala district had a total

population of 5, 95,527 out of which 3, 17,522 are males and 2, 78005 are females. Males

constitute the 53.31% and female constitutes 46.68 % of total population. Barnala has an

average literacy rate 67.8% which is 7.5% more than the 2001 Census data. The percentage of

decadal growth in population has been 13.0% during 2001-11 and sex ratio (number of females

per 1000) has been 876 in 2011 as compared to 872 in 2001. In the district 0-6 years of

population in the district has been 10.9 which is on the decreasing trend in comparison of 2001

when it was 13.3% . As per the census records 2011, in Barnala district there are 78.5% Sikhs,

19.0% Hindus, 2.2% Muslims, 0.1% Christians, Jains and Buddhists are negligible.



Environmental Impact and Mitigation Measures

Air Quality:

The main sources of air pollution due to the operation of the plant are the Boiler, process stack

/vent, pump, DG set and other stacks. Gaseous emission from fuel burning, consist of common

pollutants like PM, SO2, NO2, and HCL would be discharged into atmosphere through Stack of

suitable height as per CPCB norms. The operation of centrifuging/ filter will be done in closed

equipment to avoid any vapours coming out in the local atmosphere. The vents of centrifuges /

filters will be connected to scrubbers.

For the proposed project, computations of 24-hour average ground level concentrations were

carried out using ISCST3 model, which is a recommended model by USEPA for prediction of air quality from point area.

Table: Summary of Maximum 24-hour Incremental GLC due to the Proposed Expansion

Project Stacks

Parameters Maximum incremental GLC

(µg/m³)

Distance (Km)

Direction

PM 0.95 1.6 SE

SO2 0.64 1.6 SE

NOx 3.1 1.6 SE

HCL 0.23 1.6 SE

The nearest settlement in downwind direction is Fatehgarh channa village (towards SE)

at 1.68 km. As per baseline data of mean AAQ for PM at Fatehgarh channa village is 92

µg/m³ and with this proposed project, 0.95 µg/m³ rise in GLCs so PM level will be 92.95

µg/m³. The Particulate Matter in the study area is contributed mainly by commercial

activities and traffic movement (vehicular emissions), re-suspended dust from paved and

unpaved roads and open uncovered areas as well as from industrial activities.

Maximum baseline GLC for SO2 (Process and utilities) at downwind direction (SE) was

as 11.8 µg/m³ observed at Fatehgarh Channa village. With this proposed expansion

project SOx level may increase by 0.61 µg/m³ so post project level of SOx is 12.41µg/m³.

Maximum baseline GLC for NOx was as 22.70 µg/m³ observed at Fatehgarh channa

village. With this proposed project NOx concentration is 3.1 µg/m³ so rise in GLC of NOx

concentration is 25.80 µg/m³. It can be concluded that with the proposed project all the

AAQ parameters will remain within the NAAQ norms.

As is evident from the table and discussion above, there will be no adverse impacts on

the surrounding area (all pollutants post project GLC will be well within NAAQ norms

except PM which is already high due to natural and other commercial and traffic causes).

Highly efficient air pollution control systems have been adopted to mitigate particulate

matter as well as gaseous emissions in the ambient environment.



Noise Quality:

The main source of noise generation during operation stages are mainly from pumps, blowers, compressors, DG sets, vehicle movement for transportation of raw materials, finished goods etc. DG sets will be provided with acoustics enclosures. Mufflers, silencers, acoustics treatment of room will be done wherever required. Equipment will be maintained so that noise level does not increase due to improper maintenance. Material handling operations and movement of vehicles will be properly scheduled to minimize construction noise. Workers working in noisy areas will be given ear plugs. The noise level will be restricted within the plant boundary to meet the standards. Existing greenbelt developed within the plant premises will also act as a barrier to the propagation of noise from the factory premises. This shall further reduce the noise levels appreciably. Hence, no significant impact is envisaged.

Water Quality: Total water requirement–1800 KLD (Fresh water 1456 KLD and Recycle water 344 KLD).

Water requirement will be made available through ground water and surface water. Low TDS Effluent Treated in To ETP. ETP comprises of Four Stage, Two Stage Anaerobic, One Stage Aerobic and One Stage Tertiary. After treatment treated effluents discharge in to plantation area within premises. High TDS effluent Treated in to MEE. Condensate recovery will be reused in plant. Concentrated stream will be sent to ATFD for further treatment. MEE salt will be sold out to end users.

Solid and Hazardous Wastes Disposal:

All the solid and hazardous waste generated from the proposed unit shall be disposed as per the norm. Minor quantities of construction waste will be generated in the form of packaging material and construction waste. Proper care will be taken for handling and reduction of the solid waste generated during construction phase. ETP sludge/ process residue generated during operation phase shall be disposed as per the hazardous waste‘s management, handling and Trans-boundary movement Rule 2016 and amendment thereof.

Impact on Ecology: No national park, wildlife sanctuary, biosphere reserve exists within 10 km area of the project. No endangered or rare or threatened plant or animal species was observed within 10 km area of the project site. The impact on the surrounding ecology during the operation of the project will mainly occur from the deposition of air pollutants. Air pollution affects the biotic and abiotic components of the ecosystem individually and synergistically with other pollutants. Chronic and acute effects on plants and animals may be induced when the concentration of air pollutants exceeds threshold limits. Particulate emission and other gaseous emissions from the proposed plant are the major pollutant that may affect the ecology of the area. However, the AAQ modeling proves that in worst condition the concentration of the PM and other gaseous emission will not exceeds the AAQ standards. Further the mitigation measures have been suggested for the same. By adopting the mitigation measures suggested the impact due to operation of the proposed expansion will be negligible.

Risk Assessment and Disaster Management Plan: The hazard potential of chemicals and estimation of consequences in case of their accidental release during storage, transportation and handling has been identified and risk assessment has been carried out to quantify the extent of damage and suggest recommendations for safety improvement for the proposed facilities. Risk mitigation measures based on MCA analysis and engineering judgments are incorporated in order to improve overall system safety and mitigate the effects of major accidents.

An effective Disaster Management Plan (DMP) to mitigate the risks involved has been prepared. This plan defines the responsibilities and resources available to respond to the different types of emergencies envisaged. Training exercises will be held to ensure that all personnel are familiar with their responsibilities and that communication links are functioning effectively.



Green belt development:IOLCP has planted approx 26000 tree/shrubs and herbs in existing

greenbelt. The tree species like Eucalyptus, neem, Daikan, sadabahar, Ficus spp., jamun,

Champa, kadam gulmohar along with shrubs and herbs has been planted under existing

greenbelt. Further maintenance of the existing greenbelt shall be done on regular basis for which

IOL Chemical has already kept a budget for Rs. 20 lakhs as a capital cost.

CSR Plan: IOLCP has allocated 2.5% of the total project cost towards the Enterprise Social

Commitment (ESC) and item-wise details along with time bound action plan will be prepared and

incorporated after public hearing.

Project Benefits

Proposed expansion project will result in considerable growth of stimulating the industrial

and commercial activities in the state. Small and medium scale industries may be further

developed therefore.

The project will be beneficial in govt‘s target of increase the production capacity and yield

in the field of pharmaceuticals.

Increased revenue to the state by way of royalty, taxes and duties;

Overall Growth of the neighboring area viz. Health and family welfare; Watershed

development; Sustainable livelihood and strengthening of village Self Help Groups; and

Infrastructure development.

In operation phase, the proposed plant would require significant workforce of non-

technical and technical persons.

Migration of persons with better education and professional experience will result in

increase of population and literacy in the surrounding villages.

Civic amenities will be substantial after the commencement of project activities. The

basic requirement of the community needs will be strengthened by extending healthcare,

educational facilities to the community, building/strengthening of existing roads in the

area.

The local population will be given preference to employment on the basis of their

eligibility and company requirement. The employment potential will ameliorate economic

conditions of these families directly and provide employment to many other families

indirectly who are involved in business and service-oriented activities. The employment

of local people in primary and secondary sectors of project shall upgrade the prosperity

of the region. This in-turn will improve the socio-economic conditions of the area.



CHAPTER 8. DISCLOSURE OF CONSULTANTS

Team Composition

Declaration by Experts Contributing to this Report

Declaration by Experts Contributing to the EIA/EMP Report for expansion of APIs and Bulk

drug production unit by M/s IOL Chemical and Pharmaceutical Limited

Name of EIA Sector: Synthetic Organic Chemicals

Category: 5(f) A

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

above EIA.

EIA Coordinator:

Name: Yashwant Borbia

Signature

Period of involvement Feb 2018 to finalization of report

Contact Information: 011-30003200

Functional Area Experts

Functional Areas

Name of the Expert

Involvement

(Period and Task**)

Feb 2018 to finalization of report

Signature

Air Pollution Monitoring &

Control (AP)

Y Bordia

Air pollution monitoring.

Meteorological parameter

measurement.

Identification & assessment of quantum of emission and its

Mitigation measures.

Air Quality Modeling and Prediction

(AQ)

Mr. Sanjeev

Sharma

Ambient Air Quality monitoring

network designing.

Processing of micrometeorological

data for using in model.

Air quality modelling through ISC- Aermod for proposed prediction of impact

Noise Mr. Sanjeev

Sharma

Monitoring of noise levels of the

project site and surrounding area.

Assessment of noise level and vibration potential due to proposed

project and its mitigation measures.

Water Pollution

(WP)

Y Bordia

Water Quality monitoring network

designing.

Sampling of water samples (surface

and ground water).



Functional Areas

Name of the Expert

Involvement

(Period and Task**)

Feb 2018 to finalization of report

Signature

Monitoring of water quality.

Water Balance

Identification & assessment of quantum of water pollution and its

Mitigation measures.

ETP Suggestion.

Ecology and

Bio-diversity

Conservation

(EB)

Ratnesh Kotiyal

Conducted Ecological survey &

preparation of status report.

Application of taxonomy in resource

inventory (Flora & Fauna) List of species animals and plants

report.

Identification & assessment of ecological impact due to proposed

project and its Mitigation measures.

Solid and Hazardous Waste Management

(SHW)

Y Bordia

Identification of hazardous and non

hazardous wastes.

Reuse and recycling of solid wastes.

Handling and disposal of Non- Hazardous solid waste & Hazardous

waste.

Risk and Hazards

(RH)

P K Srivastava

Identification of hazards due to

proposed project.

Identification of hazardous

substances in the proposed project.

Preparation of risk assessment report

and onsite emergency plan.

Declaration by the Head of the Accredited Consultant Organization/authorized person

I, S.K.Jain, hereby confirm that the above-mentioned experts the EIA/EMP Report for expansion of APIs

and Bulk drug production unit by M/s IOL Chemical and Pharmaceutical Limited. I also confirm that the

consultant organization shall be fully accountable for any mis-leading information mentioned in this

statement.

Name: S.K.Jain

Signature

Designation: Director, Technical

Name of the EIA Consultant organization EQMS India Pvt. Ltd.

NABET Certificate No. and date NABET/EIA/1619/SA070 Valid upto 23rd

May2018

Documents

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