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VIRCHOW DRUGS LIMITED SY.NO. 639 (PART), IDA BONTHAPALLY,

JINNARAM MANDAL, MEDAK DISTRICT, TELANGANA

FINAL EIA REPORT

1. ENVIRONMENTAL IMPACT ASSESSMENT 2. ENVIRONMENT MANAGEMENT PLAN 3. COMPLIANCE OF TERMS OF REFERENCE 4. ANNEXURE

Project No. 0516‐21‐03 May 2016

Virchow Drugs Limited Plot No. 9, S.V. Co‐Op. Industrial Estate, IDA Jeedimetla, Hyderabad ‐500055 Phone: +91‐9246282477 E‐mail: [email protected]; [email protected]

STUDIES AND DOCUMENTATION BY TEAM Labs and Consultants B‐115‐117 & 509, Annapurna Block, Aditya Enclave, Ameerpet, Hyderabad‐500 038. Phone: 040‐23748 555/23748616, E‐mail ID: [email protected]

SUBMITTED TO STATE LEVEL ENVIRONMENT IMPACT ASSESSMENT AUTHORITY,

TELANGANA, GOVERNMENT OF INDIA



1. ENVIRONMENTAL IMPACT ASSESSMENT REPORT

Project No. 0516‐21‐03May 2016


STUDIES AND DOCUMENTATION BY TEAM Labs and Consultants B‐115‐117 & 509, Annapurna Block, Aditya Enclave, Ameerpet, Hyderabad‐500 038. Phone: 040‐23748 555/23748616, Telefax: 040‐23748666



Virchow Drugs Limited Contents

CONTENTS

Section Description Page No. E.0 Executive Summary 1‐1

1.0 Introduction of The Project 1‐1 1.1 Product Profile 1‐3 1.2 Technology 1‐4 1.3 Plant Location & Layout 1‐4 1.4 Scope of EIA Studies 1‐7 2 Process Description and Pollution control Facilities 2‐1

2.1 Process Description 2‐1 2.1.1 Process Description of Sulfanilamide 2‐2 2.1.2 Process Description of Sulfa Pyridine 2‐4 2.1.3 Process Description of Sulfa Salazine 2‐7 2.2 Utilities 2‐8 2.3 Water Requirement 2‐9 2.4 Pollution Control Facilities 2‐9

2.4.1 Water Pollution 2‐9 2.4.1.1 Process Description and Technical Specification of Effluent Treatment System 2‐11 2.4.2 Air Pollution 2‐16

2.4.2.1 Emissions from Utilities 2‐16 2.4.2.2 Emissions from Process 2‐172.4.2.3 Diffuse Emissions 2‐17 2.4.2.4 Fugitive Emissions 2‐17 2.4.3 Solvent Use and Recycle 2‐17 2.4.4 Solid Waste 2‐18 2.4.5 Noise Pollution 2‐19 3.0 Baseline Environmental Status 3‐1 3.1 Introduction 3‐1 3.2 Land Environment 3‐1

3.2.1 Physiography 3‐1 3.2.2 Geology 3‐2 3.2.3 Hydrogeology 3‐2 3.2.4 Soils 3‐4 3.3 Water environment 3‐11

3.3.1 Surface water resources 3‐113.3.1.1 Surface water Quality 3‐11 3.3.2 Ground water resources 3‐11

3.3.2.1 Quality Of Ground Water 3‐12 3.4 Air environment 3‐18

3.4.1 Meteorology 3‐18 3.4.2 Meteorological station at Industry Site 3‐21 3.4.3 Ambient air quality 3‐24 3.4.4 Scope of field study 3‐24 3.4.5 Description of sampling locations 3‐26 3.4.6 Ambient Air Quality Status 3‐28

3.4.6.1 Analysis of Poly‐Aromatic Hydrocarbons (PAH) in RSPM 3‐29 3.5 Noise environment 3‐30 3.6 Socio economic environment 3‐33

3.6.1 Demography 3‐33


3.6.1.1 Population Distribution 3‐33 3.6.1.2 Literacy 3‐34 3.6.1.3 Employment/Occupation 3‐35 3.6.2 Living standards and Infrastructure 3‐36 3.6.3 Land Utilization 3‐38 3.6.3 Project Economy 3‐39 3.7 Flora and Fauna 3‐39

3.7.1 Flora of the Core area 3‐39 3.7.2 Vegetation and flora of the Buffer zone 3‐41 3.7.3 Terrestrial Fauna of the study area 3‐45 3.7.4 Rare and Endangered animal reported in May 2013 3‐45

4 Identification of Impacts 4‐1 4.1 Identification of Impacts 4‐1 4.2 Impact Networks 4‐1

4.2.1 Air Environment 4‐2 4.2.2 Water environment 4‐2 4.2.3 Noise environment 4‐2 4.2.4 Land Environment 4‐34.2.5 Biological Environment 4‐3 4.2.6 Socio‐economic environment 4‐3 4.3 Prediction of impact on air Quality 4‐10

4.3.1 Details of Mathematical Modeling 4‐10 4.3.1.1 Model Formulation 4‐114.3.1.2 Meteorological Data 4‐12 4.3.2 Plant Emissions 4‐13

4.3.2.1 Diffuse Emissions 4‐15 4.3.2.2 Fugitive Emissions 4‐15 4.3.2.3 Air Quality Impact Predictions 4‐16 4.3.2.4 Prediction of Concentration of Solvents in the Indoor Environment Due to Solvent Loss

and Fugitive Emissions 4‐24

4.4 Prediction of Impact on Noise quality 4‐25 4.5 Prediction of Impact on water quality 4‐26 4.6 Prediction of Impact on soil 4‐26 4.7 Prediction of Impact on Socio Economics 4‐26 4.8 Prediction of Impact on local Flora and Fauna 4‐27 4.9 Prediction of Impact on Vehicular Traffic 4‐28 5 Environmental Monitoring 5‐1

5.1.1 Introduction 5‐1 5.1.2 Objectives 5‐1 5.1.3 Methodology 5‐1 5.1.4 Ambient Air Quality (AAQ) Monitoring 5‐2 5.1.5 Water Quality Monitoring 5‐3 5.1.6 Noise Level Monitoring 5‐7 5.1.7 Responsibility of Monitoring and Reporting System 5‐9 5.2 Environmental Monitoring Budget 5‐9 6 Risk Assessment and Damage Control 6‐1

6.0 Introduction 6‐1 6.1 Objectives and Scope 6‐1 6.2 Production Details 6‐2 6.3 Process Description 6‐4 6.4 Plant Facilities 6‐4


6.4.1 Production Blocks 6‐4 6.4.2 Utilities 6‐4 6.4.3 Quality Control, R&D Lab 6‐5 6.4.4 ETP and Solid waste storage 6‐5 6.4.5 Ware Houses 6‐5 6.4.6 Tank Farm Area 6‐6 6.4.7 Administrative Office 6‐6 6.4.8 Water Sump 6‐6 6.4.9 House Keeping 6‐6

6.4.10 Facility layout and design 6‐6 6.5 Hazard Analysis and Risk Assessment 6‐8

6.5.1 Introduction 6‐8 6.5.2 Hazard Identification 6‐8 6.5.3 Fire & Explosion Index (F & EI) 6‐10

6.5.3.1 Methodology 6‐10 6.5.4 Hazard and Operability Study (HAZOP) 6‐12 6.5.5 Hazard Factors 6‐14 6.5.6 Common Causes of Accidents 6‐166.6 Maximum Credible Accident and Consequence Analysis (MCACA) 6‐18

6.6.1 Methodology 6‐19 6.6.2 Identification of Vulnerable Areas 6‐20 6.6.3 Representative Accident Scenarios 6‐20 6.7 Consequence Analysis 6‐21

6.7.1 Release Models and Source strength 6‐22 6.7.2 Results of Consequence Analysis 6‐24

6.7.2.1 Analysis of Hazardous Scenarios 6‐24 6.7.2.1.1 Heat radiation effects 6‐24 6.7.2.1.2 Overpressure effects 6‐27

6.7.3 Observations 6‐27 6.7.4 Recommendations 6‐27 6.7.5 Transportation 6‐28 6.8 Disaster Management Plane 6‐29

6.8.1 Introduction 6‐29 6.8.2 Objectives Of Emergency Management Plan (On‐Site) 6‐30 6.8.3 Scope Of ONSEP 6‐31 6.8.4 Methodology Of Developing ONSEP 6‐31 6.8.5 Element Of ONSITE Emergency Plane 6‐32

6.8.5.1 Emergencies Identified 6‐33 6.8.5.2 Emergencies Organization 6‐33 6.8.5.3 Emergency Facilities 6‐33 6.8.5.4 Emergency Procedures 6‐36 6.8.5.5 Rescue and Rehabilitation 6‐37 6.8.5.6 Emergency Responsibilities 6‐38 6.8.6 Remedial Action 6‐43 6.8.7 Basic Action In Emergencies 6‐43 6.8.8 Fire Fighting Operations 6‐44


List of Tables

S.No Description Page. No. 1.1 List of products and Manufacturing Capacity – After Expansion 1‐3 1.2 List of By–Products‐ After Expansion 1‐4 2.1 List of products and Manufacturing Capacity – After Expansion 2‐1 2.2 List of By–Products‐ After Expansion 2‐1 2.3 Material Balance for Sulfanilaamide 2‐4 2.4 Material Balance forSulfa pyridine 2‐6 2.5 Material Balance for Sulfa Salazine 2‐7 2.6 List of Utilities 2‐8 2.7 Total Water balance 2‐9 2.8 Total Effluents generated and Mode of Treatment 2‐10 2.9 Effluents generated and Characteristics from process – (Product Wise) 2‐10 2.10 Effluents generated and Characteristics from process – (Stage Wise) 2‐112.11 Technical specifications of Effluent treatment System 2‐14 2.12 Technical specifications of Biological Treatment Plant 2‐15 2.13 Emission details of Pollutants from Stack 2‐16 2.14 Total Solvent Balance‐Product wise 2‐18 2.15 Total Solid Waste Generated and Disposal 2‐19 3.1 Soil Analysis Data 3‐8 3.2 Soil Test Results – Reference Tables 3‐10 3.3 Locations of Ground Water Samples 3‐13 3.4 Water analysis data ( Ground Water) 3‐16 3.5 Normal Climatrological Data 3‐19 3.6 Frequency Distributions of Wind Speeds and Wind Directions 3‐22 3.7 National Ambient Air Quality standards 3‐25 3.8 Location of Ambient Air Quality monitoring stations 3‐26 3.9 Ambient air quality statuses 3‐283.10 Chemical composition of RSPM 3‐29 3.11 Affects on Human Beings at Different Noise Levels 3‐32 3.12 Equivalent Noise levels in the Study Area 3‐32 3.13 Population Distribution – Study Area 3‐34 3.14 Literacy ‐ Study Area 3‐343.15 Employment ‐ Study Area 3‐35 3.16 Main workers study area 3‐36 3.17 Land utilization Pattern 3‐38 3.18 List of trees, shrubs and grasses found in the premises of bulk drug unit 3‐39 3.19 List of trees and shrubs found in the buffer zone of the industry 3‐41 3.20 List of grasses and sedges found in the buffer zone during the summer season 3‐44 3.21 List of vertebrates other than birds found in and around the project site 3‐46 3.22 List of Birds either spotted or reported from the areas in and around the project site. 3‐47 4.1 Salient Features of the ISCST3 Model 4‐11 4.2 Atmospheric Stability Classification 4‐13 4.3 Mixing Heights considered for Computations 4‐13 4.4 Emission Details of Pollutants from Stack 4‐14 4.5 Maximum Predicted 24 hourly GLC’s 4‐17 4.6 Predicted GLC’s at Monitoring Locations 4‐17 4.7 Cumulative Concentrations at Various Villages 4‐18 4.8 Solvent Loss and the Predicted Airborne Concentrations 4‐25 5.1 National Ambient Air Quality Standards 5‐2


5.2 Indian Standard Drinking Water Specification‐IS:10500:1991 5‐4 5.3 Noise Level Standards (CPCB) 5‐8 5.4 Environmental Monitoring Plan 5‐8 5.5 Environmental Monitoring Budget 5‐10 6.1 Proposed Manufacturing Capacity – After Expansion 6‐3 6.2 List of By‐Products 6‐3 6.3 List of Raw Materials and inventory 6‐3 6.4 List of Utilities 6‐5 6.5 Applicability of GOI Rules to Storage/Pipeline 6‐10 6.6 Degree of Hazard for F&EI 6‐12 6.7 Fire & Explosion Index for Tank farm 6‐12 6.8 Failure Rate Data 6‐17 6.9 Ignition Sources of Major Fires 6‐18 6.10 General Failure Frequencies 6‐21 6.11 Damage Due to Incident Radiation Intensities 6‐23 6.12 Radiation exposure and lethality 6‐23 6.13 Damage Due to Peak Over Pressure 6‐24 6.14 Heat Radiation Damage Distances – Tank Farm 6‐266.15 Truck Incidents – Initiating and Contributing Causes 6‐28 6.16 Transportation specific concerns 6‐29 6.17 List of Fire Extinguishers 6‐35


List of Figures S.No Description Page. No. 1.1 Location of M/s. Virchow Drugs Limited 1‐5 1.2 Plant Layout of M/s. Virchow Drugs Limited 1‐6 2.1 Process diagram of Sulfanilaminde 2‐3 2.2 Process diagram of Sulfa pyridine 2‐52.3 Process diagram of Sulfa salazine 2‐7 2.4 Schematic Diagram of Effluent Treatment System 2‐13 3.1 Site Photographs of M/s. Virchow Drugs Limited 3‐2 3.2 Base map of the study area 3‐5 3.3 Land use and land cover map of the study area 3‐6 3.4 Soil Sampling Locations 3‐7 3.5 Drainage pattern of the study area 3‐14 3.6 Water Sampling Locations 3‐15 3.7 Piper Trilinear Diagram for Ground water 3‐18 3.8 Wind Rose Diagram at Site 3‐23 3.9 Ambient air quality Locations 3‐27

3.10 Noise Sampling Locations 3‐31 4.1 Impacts Network For Air Environment 4‐4 4.2 Impacts Network For Noise Environment 4‐5 4.3 Identification of Likely Impacts For Waste Water 4‐6 4.4 Impacts Network For Land Environment 4‐7 4.5 Impacts Network For Soil Micro Flora Fauna 4‐8 4.6 Impact Network For Socio‐Economic And Cultural Environment 4‐9 4.7 Isopleths Showing 24 Hourly GLC’s of SPM 4‐194.8 Isopleths Showing 24 Hourly GLC’s of PM10 4‐20 4.9 Isopleths Showing 24 Hourly GLC’s of PM2.5 4‐21

4.10 Isopleths Showing 24 Hourly GLC’s of SO2 4‐22 4.11 Isopleths Showing 24 Hourly GLC’s of NOX 4‐23 6.1 Plant Layout of M/s. Virchow Drugs Limited 6‐76.2 Steps in Consequence Calculations 6‐22

Virchow Drugs Limited Executive Summary

Team Labs and consultants E-1

EXECUTIVE SUMMARY

Introduction

Pharmaceutical Chemicals are used for the benefit of human and animal health. The

scale of manufacturing of Active Pharma Ingredients is less compared to other

synthetic organic chemicals, which are used for the manufacture of consumer products.

India is a major producer of active pharma ingredients contributing to wellbeing of

both human and animal population of the world.

M/s. Virchow Drugs Limited obtained consent for operation for Bulk Drugs &

intermediates at Sy. No. 639 (Part), IDA Bonthapally, Jinnaram Mandal, Medak District,

Telangana. It is proposed to expand the API manufacturing capacity from 40 TPM to

130 TPM in existing area of 3 acres to meet the increasing market demands. The

expansion entails a capital cost of Rs. 2 crores towards modernization of zero liquid

discharge facility, debottlenecking by way of incorporating the advanced technology

and state of the art equipment. The proposed expansion does not involve any

additional civil construction for manufacturing blocks except utility and pollution

control related works. Prior environmental clearance is mandated by Ministry of

Environment and Forests, vide SO 1533, dated September 14, 2006 for synthetic organic

chemicals manufacturing activity. State Expert Appraisal Committee (SEAC) of

Telangana issued terms of reference to prepare EIA as mentioned in the manual of

MoEF&CC, GOI for “Synthetic Organic Chemicals Industry (dyes and dye

intermediates; bulk drugs and intermediates excluding drug formation; synthetic

rubber; basic organic chemicals, other synthetic organic chemicals and chemical

intermediates” during SEAC meeting held on 29.09.2016 as part of the environmental

clearance process. The project was exempted from public hearing process as the

industry site is located in the notified industrial area of IDA Bonthapally, Medak

district. The compliance letter from the regional office of MoEFCC, Chennai is

obtained vide letter no.Lr. No. J-11011/132/2004-IA. II



Location of the Project:

The project site is located at Sy. No. 639 (Part), IDA Bonthapally, Jinnaram Mandal,

Medak District, Telangana. The site is situated at intersection of 78021’15.06” (E) and

latitude 17039’24.70” (N). The site is surrounded by road connecting Jinnaram and

Bonthappay in north direction, SSI Company in south direction, M/s. Samkrg Pistons

and Rings Ltd., in east direction and open land in west direction. The nearest habitation

from the site is bonthapally at a distance of 1.2 Km in northeast direction. The main

approach road is Hyderabad – Narsapur passing at a distance of 2 km in east direction.

The nearest railway station is Medchal at a distance of 12.87 km in southeast direction

and the nearest airport is located at a distance of 48 km in southeast direction. Medchal

town is located at a distance of 12.8 km in southeast direction. There are no major water

bodies within the study area. Bonthapalle RF at a distance of 0.4 Km in northwest,

Jinnawaram RF at a distance of 6.5 Km in southwest, Mangapet RF at a distance of 5 Km

in east, Royyapalli RF at a distance of 7 Km in east, Wailal RF at a distance of 8 Km in

south, Dundigal RF at a distance of 8.5 Km in southeast, Nagawaram RF at a distance

of 8 Km in northwest, Mambapur RF at a distance of 6.5 Km in northwest, Nallavalli RF

at a distance of 8 Km in northwest, Pottaguda RF at a distance of 9 Km in southwest

directions respectively. There are no ecologically sensitive areas like national parks,

and sanctuaries within 10 km radius of the site. The site is located at a distance of 11.5

Km from the critically polluted area of Patancheru and Bollaram Industrial estates.

Product Profile

The manufacturing capacity of permitted and after expansion is presented in following.

Manufacturing Capacity S.No Name of Product Capacity (TPM)

Permitted After Expansion

Group - I 1 Sulfanilamide 40 127.5

Group - II 2 Sulfarpyridine 25 100 3 Sulfa salazine 5 30 Total - II 30 130

Worst Case - Any One Group 40 130

List of By-Products – After Expansion



S.No Name of product Name of By -Product Capacity Kg/day TPM

1 Sulfa salazine Dil. Sulfuric acid 2650 79.5 Dil . Acetic acid 2850 85.5

Manufacturing Process

Chemical synthesis produces majority of API’s currently in the market. Chemical

synthesis consists of four steps - reaction, separation, purification, and drying. Large

volumes of solvents are used during chemical syntheses, extractions, and solvent

interchanges. The manufacturing process of the above mentioned molecules involve

various types of reactions like acetylyzation, protection, deprotection etc. The

manufacturing process of all the compounds, reactions involved, material balance are

presented in chapter 2 of EIA report.

Utilities

The proposed expansion requires additional steam. It is proposed to install 4 TPH coal

fired boiler and change the fuel of existing 3 TPH oil fired boiler to 3 TPH coal fired

boiler. The required steam is drawn from proposed 4 TPH coal fired boiler and existing

3 TPH boiler, while the existing 1TPH coal fired boiler will be dismantled after

expansion. No additional DG sets are proposed, existing DG sets of capacity 500 and

200 KVA shall be kept as standby during load shut down.The list of utilities is

presented in the following Table.

List of Utilities S.No Description Capacity

Existing Proposed Total after Expansion 1 Coal Fired Boilers 1 x 1 TPH* 1 x 4 TPH 1 x 4 TPH

1 x 3 TPH 2 Oil Fired Boiler 1 x 3 TPH** --- --- 3 DG Set# 1 x 200 KVA

1 x 500 KVA 1 x 200 KVA

1 x 500 KVA * Shall be dismantled after expansion ** Fuel changed from oil to coal. # DG sets will be used during load shut down by TSTRANSCO

Water Requirement

Water is required for process, scrubbers, washing, cooling tower makeup, steam

generation and domestic purposes. The total water requirement shall be increased from



97.33 KLD to 249.5 KLD after expansion out of which 159.5 KLD will be fresh water and

balance shall be recycled water. The required water shall be drawn from TSIIC

(Industrial supply) in addition to reuse of treated wastewater. The water balance for

daily consumption is presented in the following table;

Total Water Balance – After Expansion Purpose INPUT (KLD) OUTPUT (KLD)

Fresh Water Recycled Water Loss Effluent Process 42 51.97* Washings 5 5 Scrubber 3 3 Boiler Feed 19 16 3 Cooling Tower 75 90 135 30 RO/DM Plant 4.5 4.5 Domestic 5 0.5 4.5 Gardening 6 6 Gross Total 159.5 90 157.5 101.97 Total 249.5 259.47 * Process effluents contain soluble raw materials, byproducts, solvents etc.

Baseline Environmental Data

The baseline data was collected in the study area during the months of February 2016

to May 2016 parallel for M/s. Granules India Limited (formerly known as Auctus

Pharma Unit III) and Sri Gayatri Drugs Pvt. Ltd., which obtained TOR simultaneously.

The baseline data involves collection of Samples of ground water, surface water and

soil, monitoring of ambient air quality, noise levels, ecological status and

meteorological parameters. The analytical results show that the values are within the

prescribed limits for air quality. The ground water quality is observed to be above the

limits for potable purpose when compared to the prescribed standards of IS: 10500 –

2012 at few locations.

Identification and Quantification of Impacts

The impact assessment report has identified various sources of pollution and quantified

the pollution loads due to the expansion. It has also identified the technologies to be

adopted for the mitigation and control of the same. The sources of pollution are air

emissions from utilities and process; liquid effluents from process, utilities and

domestic sources; solid wastes from process, treatment systems and utilities; and noise

pollution from utilities, and process equipment.



Impacts on Air quality: The impacts on air quality shall be due to the emissions from,

Coal Fired Boilers and DG sets. The incremental concentrations are quantified using

ISC-AERMOD model based on ISCST3 Algorithm for all the four co-located units. The

results indicate marginal increase in ambient air quality concentration. The predicted

values for SPM, PM10, PM2.5, SO2 and NOx are 5.19, 2.10, 0.94, 6.89 and 4.10 μg/m3

respectively at a distance of 0.5 Km in northeast direction, and the cumulative values of

baseline air quality combined with predicted values are found to be within the

prescribed limits of National Ambient Air Quality Standards.

Impacts on Water: Water is essentially used for process, utilities and domestic

purposes. The total fresh water required of quantity 159.5 KLD after expansion will be

drawn from TSIIC supply in addition to recycled water of 90 KLD. No impact on water

quality is expected due to the discharge of effluents as zero liquid discharge in

envisaged, which ensures reuse of treated effluents for cooling tower makeup. There is

no usage of treated water for on land irrigation.

Impacts on Noise quality: The noise levels may increase due to motors, compressors,

DG set and other activities. The predicted cumulative noise levels (as calculated by the

logarithmic model without noise attenuation) ranged between 55 and 75 dB(A) at

distances of 10 to 15m. The impact is found to be insignificant beyond the premises.

Impacts on Soil: The solid wastes generated from process, utilities and effluent

treatment plant may have significant negative impacts if disposed indiscriminately.

Hence appropriate measures for storage and disposal of solid wastes need to be

implemented.

Impacts on Ecology: There are no endangered species of flora and fauna in the impact

area. Hence there is no significant impact on ecology.

Impacts on Socio Economy: There is a potential for direct/indirect employment for the

locals. The impact area with low industrial density will have positive benefits due to

the project.

Environment Management Plan



The management plan is drawn in consultation with project proponents and technical

consultants after evaluating a number of technologies available for mitigation and

control of pollution. The EMP is drawn to address the impacts monitored, identified

and predicted. The EMP addresses the impacts identified during construction and

operation stages. The impacts during construction stage are temporary and less

significant, the management plan for impacts identified during operation stage is

detailed below.

Liquid Effluents

Liquid effluents generated from manufacturing processes causes soil contamination if

untreated effluents are disposed on land. The effluents generated in the process,

separation techniques and purification contain organic residues and inorganic

materials, solvents, and traces or products. These effluents contain both organic and

inorganic salts in various quantities leading to high COD and TDS levels respectively.

The details of process effluent segregation are presented in the Environment

Management Plan. Typical effluent characteristics and mode of treatment are presented

as follows:

Total Effluent Generated and Mode of Treatment Description Quantity (KLD) Mode of Treatment


HTDS Effluents (TDS & COD> 15000 mg/l) Process 9.045 51.97 Sent to Stripper followed by forced

evaporator and ATFD. Stripper Condensate is reused in process. Evaporator and ATFD Condensate sent to Biological treatment plant followed by RO. RO rejects sent to Forced evaporator and permeate are reused in cooling towers make-up.

Scrubber Effluent 3 Sent to Forced evaporator followed by ATFD, Biological treatment plant and RO. RO/DM rejects 4.5

Total - I 9.045 59.47 LTDS Effluents (TDS & COD< 15000 mg/l)

Washings 1 5 Sent to Biological Treatment System followed by RO. RO permeate reused for cooling towers makeup. RO rejects sent to Forced evaporator.

Boiler Blow downs 0.5 3 CT Blow downs 1 30 Domestic 1 4.5 Total - II 3.5 42.5 Grand Total (I+II) 12.545 101.97



Effluent Treatment System

The Effluent management system is developed to ensure `Zero Liquid Discharge’. The

effluents are segregated into two streams High COD/TDS and Low COD/TDS streams.

The effluents are segregated stream wise based on the characteristics of effluents, i.e.,

less than 15000 mg/l of TDS and COD are considered as low TDS effluents, while the

others are considered as high COD/TDS effluents.

The High TDS/ COD Effluents

The treatment system for treating High TDS/ COD effluents consists of Equalization,

Neutralization, Settling tank, Stripper, forced Evaporator followed by Agitated Thin

Film Dryer (ATFD). The organic distillate from the stripper is reused in process and

aqueous bottom from stripper is sent to forced evaporator followed by ATFD for

evaporation. The condensate from the forced evaporator and ATFD are sent to ETP

(Biological). Salts from ATFD are disposed to TSDF.

The Low TDS/ COD Effluents:

These effluents along with the condensate from forced evaporator and ATFD are

treated in primary treatment consisting of equalization, neutralization, and primary

sedimentation followed by secondary biological treatment consisting of aeration tank

and clarifier. The treated effluents after biological treatment are subjected to tertiary

treatment in a reverse osmosis system. Permeate from RO is reused for cooling tower

and rejects are sent to forced evaporator followed by ATFD. Sludge from various units

of Biological treatment are thickened in sludge handling system and sent to TSDF

Air Pollution

The sources of air pollution are from proposed 4 TPH Coal fired boilers and existing 3

TPH coal fired boiler (fuel change from oil fired to coal fired). It is proposed to

dismantle existing 1 TPH coal fired boiler after expansion. The proposed air pollution

control equipment for 4 TPH and 3 TPH Coal fired boilers is Multi cone cyclone

separators. DG sets shall be provided with stack heights based on the CPCB formula for

effective stack height.

Solvent Use and Recycle



Solvents are used for extraction of products and as reaction medium. Used solvents

recovered by distillation for reuse. The recovered solvents are reused.



Solid Waste

Solid wastes are generated from process, solvent distillation, effluent treatment system,

DG sets and boilers. Stripper distillate reuse in process. The evaporation salts are sent

to TSDF. Filter media like activated carbon and catalyst are sent to TSDF. Waste oil

and used batteries from the DG sets are sent to authorized recyclers. Sludge from

effluent treatment plant is considered hazardous and the same is sent to TSDF. Other

solid wastes expected from the unit are containers, empty drums which are returned to

the product seller or sold to authorized buyers after detoxification. Coal ash from boiler

is sold to brick manufacturers.

Noise Pollution

Noise is anticipated from motors, compressors, centrifuges and DG sets. DG set shall be

provided with acoustic enclosure. Motors and compressors shall be mounted properly

to ensure reduction of noise and vibration. Employees working in noise generating

areas shall be provided with appropriate personnel protective equipment.

Occupational Safety and Health

Direct exposure to pharmaceuticals or its raw materials may affect health of employees.

Direct exposure to hazardous materials is eliminated by providing closed handling

facilities. Personal Protective Equipment (PPE) i.e., hand gloves, safety goggles, safety

shoes, safety helmets, respiratory masks etc. are provided to all the employees working

in the plant. Company has a policy of providing PPEs to all personnel including

contract workers.

Prevention, maintenance and operation of Environment Control Systems

The pollution control equipment and effluent treatment systems will be periodically

monitored and checked for their performance and preventive maintenance will be

adopted. The environmental monitoring results will be evaluated to identify the

problems/ under performance of the equipment. Necessary steps will be taken to

rectify the problems/defects, if any. The management agrees that the evaluation of the

performance of pollution control measures and occupational safety measures are

adopted to ensure their effectiveness



Transport systems

Raw materials and finished products are transported by road. Sufficient parking

facilities are provided for vehicles loading and unloading of goods. As plant is located

away from habitation there will not be any unauthorized shop or settlements along the

road connecting the plant site. There will be 2 truck trips per day to the factory. The

vehicles are provided with parking space near the gate, and road safety signage is

placed in the battery limit. Drivers of the vehicles will be provided with TREM cards

and will be explained the measures to be adopted during various emergencies.

Reduce, Recycle and Reuse

A number of measures are proposed to achieve high yields and reduce generation of

wastes. It shall be endeavor of the R&D team to improve yields through constant

research and development activities. The solvents shall be recycled for reuse in the

process after distillation. Mother liquors from the first crop shall be reused for process.

Treated effluent shall be reused for cooling tower makeup.

Green Belt Development

Green belt is recommended as one of the major components of EMP. The management

emphasizes the development of further greening of the site in an area of 0.99 acres to

enhance environmental quality through mitigation of fugitive emissions, attenuation of

noise levels, balancing eco-environment, consumption of treated effluent, prevention of

soil erosion, and creation of aesthetic environment.

Post Project Monitoring

Environmental monitoring for water, air, noise and solid waste quality shall be

conducted periodically either by proponent or third party. The frequency of

monitoring and the quality parameters shall be as suggested by the Ministry of

Environment and Forests, Government of India.

Environment Management Department

The Environment Management Cell of the project shall be headed by the Production

Manager, and shall be assisted by 4 no.s operators, 3 no.s of chemist and 3 nos. of

fitters.

Virchow Drugs Limited Environmental Impact Assessment Report

Team Labs and consultants 1-1

1.0 INTRODUCTION

1.0 Introduction of the Project (Terms of Reference No. 2 (i) and (ii))

The pharmaceutical industry is an important component of health care systems

throughout the world; it is comprised of many public and private organizations that

discover, develop, manufacture and market medicines for human and animal health.

The pharmaceutical industry is based primarily upon the scientific research and

development (R&D) of medicines that prevent or treat diseases and disorders. Modern

scientific and technological advances are accelerating the discovery and development

of innovative pharmaceuticals with improved therapeutic activity and reduced side

effects. Industrial chemicals are used in researching and developing active drug

substances and manufacturing bulk substances and finished pharmaceutical products.

Chemical synthesis produces the majority of drugs currently on the market. Chemical

synthesis consists of four steps - reaction, separation, purification, and drying. Large

volumes of solvents are used during chemical syntheses, extractions, and solvent

interchanges. The bulk drug manufacturing process utilizes various process

equipment and chemical methods. Sources of emissions include dryers, reactors,

distillation units, storage and transfer of materials, filtration, extraction, centrifugation,

and crystallization. Chemical synthesis consists of one or more batch reactions

followed by separation and purification steps utilizes organic and inorganic reactants,

solvents, and catalysts, and is solvent-intensive. Waste streams generated are numerous

and complex due to the raw materials used and the varied nature of operations.

Organic synthesis generates a mother liquor containing unconverted reactants, by-

products, and residual product in a solvent or aqueous base, as well as acids, bases,

metals, etc. Other sources of waste result from equipment cleaning, spills, filtrates,

concentrates, wet scrubbers, and miscible solvents.

The scientific research and development in active pharma ingredient manufacturing is

focused on increasing the yields and reducing the wastes, using alternative

manufacturing methods etc. In this context the pharmaceutical manufacturing is

viewed as an environmentally hazardous activity. Accordingly Ministry of



Environment and Forests, GOI mandated prior environmental clearance for synthetic

organic chemical manufacturing units vide S.O.1533 dt. 14.09.2006.

M/s. Virchow Drugs Limited obtained consent for operation for Bulk Drugs &

intermediates at Sy. No. 639 (Part), IDA Bonthapally, Jinnaram Mandal, Medak District,

Telangana. It is proposed to expand the API manufacturing capacity from 40 TPM to

130 TPM in existing area of 3 acres to meet the increasing market demands. The

expansion entails a capital cost of Rs. 2 crores towards modernization of zero liquid

discharge facility, debottlenecking by way of incorporating the advanced technology

and state of the art equipment. The proposed expansion does not involve any

additional civil construction for manufacturing blocks except utility and pollution

control related works. Prior environmental clearance is mandated by Ministry of

Environment and Forests, vide SO 1533, dated September 14, 2006 for synthetic organic

chemicals manufacturing activity. State Expert Appraisal Committee (SEAC) of

Telangana issued terms of reference to prepare EIA as mentioned in the manual of

MoEF&CC, GOI for “Synthetic Organic Chemicals Industry (dyes and dye

intermediates; bulk drugs and intermediates excluding drug formation; synthetic

rubber; basic organic chemicals, other synthetic organic chemicals and chemical

intermediates” during SEAC meeting held on 29.09.2016 as part of the environmental

clearance process. The project was exempted from public hearing process as the

industry site is located in the notified industrial area of IDA Bonthapally, Medak

district. The compliance letter from the regional office of MoEFCC, Chennai is

obtained vide letter no.Lr. No. J-11011/132/2004-IA. II

M/s. Virchow Drugs Limited is conscious of its responsibility towards the society in

minimizing the pollution load due to the proposed expansion and accordingly decided

to carry out the Environmental Impact Assessment to identify the negative and positive

impacts and to delineate effective measures to control the pollution and to mitigate the

environmental pollution. M/s. Virchow Drugs Limited has appointed Team Labs and

Consultants for the preparation of Environmental Impact Assessment report.

Immediately after the receipt of the work order for the preparation of EIA report, the

collection of primary (field data) and secondary (data available with various state and



central government agencies) data has begun. Reconnaissance survey of the region

was carried out during December 2014, and various sampling locations to monitor

environmental parameters have been identified. Subsequently, monitoring has

commenced for collection of data on meteorology, ambient air quality, surface and

ground water quality, soil characteristics, noise levels flora and fauna at the specified

locations during February 2016 to May 2016. The other studies such as socio-economic

profile, land use pattern etc are based on secondary data collected from various

Government agencies and validated through the primary surveys. The Ambient air

monitoring locations have been selected based on the initial Air dispersion Modeling

carried out by using the meteorological data generated at India Meteorological

Department (IMD).

Field team of M/s. Team Labs and Consultants worked in the study area during

February 2016 to May 2016 parallel for nearby units namely M/s. Granules India

Limited (formerly known as Auctus Pharma Unit III) and Sri Gayatri Drugs Pvt. Ltd,

which obtained TOR simultaneously. Base line data for various environmental

components i.e., air, water, soil, noise and flora and fauna and socio economic status of

people was collected in a circular area of 10 km radius by taking the industry site as the

center point, to assess the existing environmental status as per the guidelines specified

by Ministry of Environment and Forests (MoEF), Government of India. This report

presents the results of environmental impact assessment study along with the

environmental management plan, necessary to avoid or mitigate the observed

environmental impacts of the proposed bulk drug manufacturing unit.

1.1 Product Profile Terms of Reference No. 3(ii) & (iii))

The manufacturing capacity of permitted and after expansion is presented in Table 1.1

and list of by-products presented in Table 1.2.

Table 1.1 Manufacturing Capacity S.No Name of Product Capacity (TPM)

Permitted After Expansion Group - I

1 Sulfanilamide 40 127.5 Group - II

2 Sulfarpyridine 25 100 3 Sulfa salazine 5 30



Total - II 30 130 Worst Case - Any One Group 40 130

Table 1.2 List of By-Products – After Expansion S.No Name of product Name of By -Product Capacity

Kg/day TPM 1 Sulfa salazine Dil. Sulfuric acid 2650 79.5

Dil . Acetic acid 2850 85.5 1.2 Technology The technology for the product profile is indigenous based on synthetic organic

chemistry. The product profile has been finalized based on the market demand and

the technology compatibility. The synthesis involves reaction of fine chemicals in a

solvent medium, followed by separation and purification.

1.3 Plant Location & Layout (Terms of Reference No. 12)


Medak District, Telangana. The site is situated at intersection of 78021’15.06” (E) and

latitude 17039’24.70” (N). The site is surrounded by road connecting Jinnaram and

Bonthappay in north direction, SSI Company in south direction, M/s. Samkrg Pistons

and Rings Ltd., in east direction and open land in west direction. The nearest

habitation from the site is bonthapally at a distance of 1.2 Km in northeast direction.

The main approach road is Hyderabad – Narsapur passing at a distance of 2 km in east

direction. The nearest railway station is Medchal at a distance of 12.87 km in southeast

direction and the nearest airport is located at a distance of 48 km in southeast direction.

Medchal town is located at a distance of 12.8 km in southeast direction.There are no

major water bodies within the study area. Bonthapalle RF at a distance of 0.4 Km in

northwest, Jinnawaram RF at a distance of 6.5 Km in southwest, Mangapet RF at a

distance of 5 Km in east, Royyapalli RF at a distance of 7 Km in east, Wailal RF at a

distance of 8 Km in south, Dundigal RF at a distance of 8.5 Km in southeast,

Nagawaram RF at a distance of 8 Km in northwest, Mambapur RF at a distance of 6.5

Km in northwest, Nallavalli RF at a distance of 8 Km in northwest, Pottaguda RF at a

distance of 9 Km in southwest directions respectively. There are no ecologically

sensitive areas like national parks, and sanctuaries within 10 km radius of the site. The

site is located at a distance of 11.5 Km from the critically polluted area of Patancheru



and Bollaram Industrial estates. The location map and site layout is as shown in Fig 1.1

and Fig 1.2.



Fig 1.1 Location of M/s. Virchow Drugs Limited (Terms of Reference No. 4(ii))



Fig 1.2 Plant Layout of M/s. Virchow Drugs Limited

(Terms of Reference No. 4(vi) &4(viii))



1.4 Scope of EIA Studies

EIA study involves three basic components, viz. identification, prediction and

evaluation of impacts. The scope of the EIA study incorporating the Standrad Terms

of reference (TOR) prescribed in the manual of MoEF&CC, GOI for “Synthetic

Organic Chemicals Industry (dyes and dye intermediates; bulk drugs and

intermediates excluding drug formation; synthetic rubber; basic organic chemicals,

other synthetic organic chemicals and chemical intermediates is as under:

• An intensive reconnaissance and preliminary collection of environmental

information to plan field study.

• Field studies to collect preliminary information, particularly on the quality of

the physical environment. Experienced scientists and engineers will collect the

data.

• Base line data generation and characterization of air, water, soil, noise and

vegetation in the ten kilometer radius area (impact zone) over a period of Three

months.

• A thorough study of the process including provisions for pollution control, and

environmental management that includes prediction of impacts and relevant

mathematical modeling.

• Preparation of Environmental Monitoring Program.

• Preparation of Environmental Management Plan suggesting suitable methods

for mitigating and controlling the pollution levels. Environmental Monitoring

Plan is suggested for monitoring the pollution loads at various facilities in the

premises and to ensure compliance with the statutory requirements.


2-1 Team Labs and Consultants

2.0 PROCESS DESCRIPTION AND POLLUTION CONTROL FACILITIES

M/s. Granules India Limited proposes to expand the API manufacturing capacity from 40

TPM to 130 TPM in existing area of 3 acres at Sy. No. 639 (Part), IDA Bonthapally, Jinnaram

Mandal, Medak District, Telangana. The unit obtained environmental clearance vide letter

no. J-11011/132/2004-IA II (I) dated 08.02.2005 and has consent to operate vide letter no.

APPCB/RCP/RCP/15960/CFO& HWM/HO/2013-5929 dated 27.12.2013. The manufacturing

capacity of permitted and proposed products presented in Tables 2.1 and list of By-products

after expansion is presented in Table 2.2.

Table 2.1 Manufacturing Capacity S.No Name of Product Capacity (TPM)





Table A-2 List of By-Products – After Expansion S.No Name of product Name of By -Product Capacity


Dil . Acetic acid 2850 85.5

2.1 Process Description: Terms of Reference No. 3(viii))

The manufacturing process for the above mentioned products involves chemical synthesis

utilizing mainly organic chemicals as raw materials in batch process. Typically, a series of

chemical reactions are performed in multi-purpose reactors and the products are isolated by

extraction, crystallization and filtration. The finished products are usually dried, and milled.

The manufacturing process of each product, reaction scheme, material balance and flow

diagram is presented in the following pages.



2.1.1 Process Description of Sulfanilamide

Reaction of Sulfanilamide

Stage I:

Stage II:

Process Description for Sulfanilamide

Stage I: Acetyl sulfanilyl chloride is reacted with Ammonia to give Acetyl Sulfanilamide

which on hydrolysis with caustic soda gives Sodium salt of 4-Amino-sulfanilamide this on

neutralization with Sulphuric acid gives technical sulfanilamide

Stage II: The technical sulfanilamide is recrystallized in water using Activated carbon on

cooling pure Sulfanilamide is separated. The process flow diagram is presented in Fig 2.1

and material balance is presented in Table 2.3.

NHCOCH3 NHCOCH3

SO2Cl SO2NH2

ASC Ammonia Acetyl sulfanilamide Ammonium chloride (233.5) (2 X 17) (214) (53.5)

+ 2 NH3 + NH4 Cl

NHCOCH3 NH2

SO2 NH2 SO2NH2

214 3x40 98 172 82

+ 3 NaOH + H2SO4 + CH3COONa + Na2SO4 + 2H2O

Sulfanilamide Sodium Acetate Acetyl

Sulfanilamide

Sodium Sulphate

Water

2x18

Sodium Hydroxide

Sulfuric acid

142



Fig 2.1 Process Flow Diagram of Sulfanilamide

S T A G E - I

A M M O N I A

W A T E R

R E C O V E R Y

A M M O N I A

W A S T E W A T E R

I N O R G A N I C

A M M O N I A U M C H L O R I D E

A C E T Y L S U L F A N I L Y L C H L O R I D E

A C E T Y L S U L F A N I L A M I D E

S T A G E - I I S U L P H U R I C A C I D

C S F L A K E S

A C T I V A T E D C A R B O N

W A T E R

S P E N T C A R B O N

R E C O V E R Y

W A S T E W A T E R

L O S S E S

W A T E R

W A T E R W A T E R F R O M R E A C T I O N

I N O R G A N I C

S O D I U M A C E T A T E , S O D I U M S U L P H A T E

O R G A N I C A C E T Y L S U L F A N I L A M I D E



Table 2.3 Material Balance for Sulfanilamide Stage I Input Quantity

(Kg/day) Output Quantity

(Kg/day) Remarks

Acetyl Sulfanyl chloride 6435.8 Stage I Product 5868.8 to stage II Ammonia 937.1 Ammonium chloride 1467.2 To waste water Water 8000 Acetyl Sulfanyl chloride 32.2 To waste water Ammonia 4.7 To waste water Water 8000 To waste water Total Input 15372.9 Total Output 15372.9 Stage II Input Quantity


(Kg/day) Remarks

Stage I Product 5868.8 Sulfanilamide 4250.0 Final product Sodium hydroxide 3621.1 Sodium acetate 2026.2 To Waste water Sulfuric acid 3225.1 Sodium Sulfate 4673.4 To Waste water Activated carbon 125 Stage I Product 581 To waste water Water 34000 Activated carbon 125.0 Organic Residue Water 35184.5 To Waste water Total Input 46840.0 Total Output 46840.3

2.1.2 Process Description of Sulfa Pyridine Reaction of Sulfa Pyridine

Process Description for Sulfa Pyridine

2-Aminopyridine is condensed with Acetyl sulfanilyl chloride in presence of Toluene-

Pyridine medium to give Acetyl sulfa pyridine. This on hydrolysis with caustic soda and

subsequent recovery of Toluene-pyridine mixture gives Sodium salt of sulfa pyridine. This

on Activated carbon treatment followed by neutralization with Sulphuric Acid gives Sulfa

pyridine pharma. The process flow diagram is presented in Fig 2.2 and material balance is

presented in Table 2.4.

249

S

O

O

N H

N

SULFA PYRIDINE

+ CH3COONa + Na2SO4 + NaCl + 3H2O

Sodium Acetate 82

Sodium Sulphate 142

Water 3x18

Sodium chloride 58.5

NH2

NHCOCH3

SO2Cl

N

NH2

ASC 233.5

2-Amino Pyridine

94

Sodium Hydroxide 4x 40

+ + 4NaOH + H2SO4

Sulfuric acid 98



Fig 2.2 Process Flow Diagram of Sulfa Pyridine

2 -AMINO PYRIDINE

WATER

RECOVERIES

LOSSES SULPHURIC ACID

CS LYE

CS FLAKES

TOLUENE

PYRIDINE

PYRIDINE

TOLUENE

PYRIDINE TOLUENE WATER

WATER WATER FROM REACTION

WASTE WATER

INORGANIC

EDTA

HYDROSE

SODIUM CHLORIDE, SODIUM ACETATE, SODIUM SULPHATE

ACETYL SULFANILYL CHLORIDE

SULFA PYRIDINE

ORGANIC

SALT

SPENT CARBON

CITRIC ACID

ACTIVATED CARBON



Table 2.4 Material Balance for Sulfa Pyridine Input Quantity


(Kg/day) Remarks

Acetyl Sulfanilyl chloride

4007.1 Sulfapyridine 3333 Final product

2-Amino pyridine 1480.4 Sodium acetate 1097.6 To waste water Sodium hydroxide 2443.7 Sodium sulfate 2437 To waste water Sulfuric acid 1682 Sodium chloride 783.1 To waste water Toluene 8900 Water formed in reaction 722.8 To waste water Pyridine 5350 Toluene Recovered 8633 Recovered & reused Water 22000 Toluene Loss 80.1 Fugitive Loss Hydrose 33 Toluene to Wastewater 186.9 To waste water Ethylene diamine tetra acetic acid (EDTA)

6 Pyridine Recovered 5189.5 Recovered & reused

Citric acid 6 Pyridine Loss 48.2 Fugitive Loss Activated Carbon 100 Pyridine to Wastewater 112.4 To waste water Acetyl Sulfanilyl chloride 881.6 To waste water 2-Amino pyridine 222.0 To waste water Activated carbon 100 Organic residue Hydrose 33.3 To waste water Citric acid 6 To waste water EDTA 6 To waste water Water 22136 To waste water Total Input 46007.9 Total Output 46008.3



2.1.3 Process Description of Sulfa Salazine Reaction of Sulfa Salazine

Process Description for Sulfa Salazine

Sulfa pyridine is diazotized using sodium nitrite and dilute hydrochloric acid. This mass is

added to sodium salt of salicylic acid solution in cold condition. The technical product was

isolated by neutralizing with hydrochloric acid. Technical product is purified in Dilute

H2SO4 and Acetic acid. The dilute sulphuric acid is recovered and sold as bi product.

The above purified product is dissolved in sodium hydroxide and on activated carbon

treatment and subsequent neutralization with Sulphuric acid gives Sulfa Salazine. The

process flow diagram is presented in Fig 2.3 and material balance is presented in Table 2.5.

Fig 2.3 Process Flow Diagram of Sulfa Salazine

S

O

O

N H

N

SULFA PYRIDINE

COOH

OH

SALICYLIC ACIDSodium Nitrite

249 138 69

__

N H2

+ + NaNO2 + 2NaOH + 3 HCl

Sodium Hydroxide

Hydro chloric Acid

2 x 40 3 x 36.5

N

S

O

O

NH

N

SULFA SALAZINE

N

COOH

O H

+ 3 NaCl + 4 H2O

Sodium Chloride

Water

398.3 3 x 58.5 4 x 18

3 3 % H C L

S O D I U M N I T R A T E

S A L I C Y L I C A C I D

C S F L A K E S

A C T I V A T E D C A R B O N

S U L F A P Y R I D I N E

E D T A

A C E T I C A C I D S P E N T C A R B O N

S O D I U M C H L O R I D E S O D I U M S U L P H A T E

O R G A N I C

S U L F A P Y R I D I N E S U L F A S A L A Z I N E T E C H

W A S T E W A T E R

W A T E RW A T E R F R O M R E A C T I O N , H C L , C S L Y E

I N O R G A N I C

R E C O V E R I E S

W A T E R

L O S S E S

B Y P R O D U C T D I L S U L P H U R I C A C I D

W A T E R

A C E T I C A C I D

S U L P H U R I C A C I D



Table 2.5 Material Balance for Sulfa Salazine Input Quantity


(Kg/day) Remarks

Sulfapyridine 949.9 Sulfa salazine 1000 Final product Salicylic acid 526.5 Sodium chloride 669.5 To waste water Sodium nitrite 263.2 Water formed in reaction 251.2 To waste water Sodium hydroxide 1100 Acetic acid Recovered 1624.5 Recovered &

reused Hydrochloric acid 418 Acetic acid Loss 13.7 Fugitive Loss Activated Carbon 40 Acetic acid to waste water 71.8 To waste water Ethylene diamine tetra acetic acid (EDTA)

10 Sulfapyridine 324.8 To waste water

Acetic acid 2850 Salicylic acid 180 To waste water Sulfuric acid 2500 Activated Carbon 40 To spent carbon Water 20000 EDTA 10 To waste water Dil.Acetic acid(40%) 2850 By product Dil. Sulfuric acid(60%) 2650 By product Sodium nitrite 90 To waste water Sodium sulfate 1318.9 To waste water Water 17563.2 To waste water Total Input 28657.6 Total Output 28657.7

2.2 Utilities



boiler. The required steam is drawn from proposed 4 TPH coal fired boiler and existing 3

TPH boiler, while the existing 1TPH coal fired boiler will be dismantled after expansion.

No additional DG sets are proposed, existing DG sets of capacity 500 and 200 KVA shall

be kept as standby during load shut down. The list of utilities is presented in Table 2.6.

Table 2.6 List of Utilities S.No Description Capacity



1 x 500 KVA 1 x 200 KVA


.



2.3 Water Requirement (Terms of Reference No. 3(vii))

Water is required for process, scrubbers, washing, cooling tower makeup, steam generation

and domestic purposes. The total water requirement shall be increased from 97.33 KLD to

249.5 KLD after expansion out of which 159.5 KLD will be fresh water and balance shall be

recycled water. The required water shall be drawn from TSIIC (Industrial supply) in

addition to reuse of treated wastewater. The water balance for daily consumption is

presented in Table 2.7

Table 2.7 Total Water Balance – After Expansion Purpose INPUT (KLD) OUTPUT (KLD)

Fresh Water Recycled Water Loss Effluent Process 42 51.97* Washings 5 5 Scrubber 3 3 Boiler Feed 19 16 3 Cooling Tower 75 90 135 30 RO/DM Plant 4.5 4.5 Domestic 5 0.5 4.5 Gardening 6 6 Gross Total 159.5 90 157.5 101.97 Total 249.5 259.47

* Process effluents contain soluble raw materials, byproducts, solvents etc. 2.4 Pollution Control Facilities: Liquid Effluents, air emissions and solid wastes generated are the major pollutants from the

process operations of bulk drug manufacturing. The pollution control measures proposed to

treat/mitigate the emissions and effluents are described as follows.

2.4.1 Water Pollution:

The effluents generated in the process, separation techniques and during purification

contain organic residues and inorganic raw materials, solvents, and products. Hence the

effluents contain both organic and inorganic salts in various quantities leading to high COD

and TDS levels respectively. Effluents from process, washings, Scrubbing media, and utility

blow downs will be sent to the effluent treatment system. The treated effluent will be

reused for cooling towers. The domestic waste water will be sent to biological treatment

plant along with LTDS effluents. The total effluent generated and mode of treatment is



presented in Table 2.8. Quantity and quality of effluents generated from process product

wise and stage wise is presented in Table 2.9 and 2.10.

Table 2.8 Total Effluent Generated and Mode of Treatment – After Expansion Description Quantity (KLD) Mode of Treatment


HTDS Effluents (TDS & COD> 15000 mg/l) Process 9.045 51.97 Sent to Stripper followed by forced

evaporator and ATFD. Stripper Condensate is reused in process. Evaporator and ATFD Condensate sent to Biological treatment plant followed by RO. RO rejects sent to Forced evaporator and permeate are reused in cooling towers make-up.

Scrubber Effluent 3 Sent to Forced evaporator followed by ATFD, Biological treatment plant and RO. RO/DM rejects 4.5




Table 2.9 Effluent Generated and Characteristics from Process – Product Wise

S.No Name of Product Quantity (Kg/Day) Conc. (mg/l) Water Input

TDS COD Total Effluent

TDS COD

Group - I 1 Sulfanilamide 42000 8171 730 51969.4 157236 14053

Group - II 2 Sulfarpyridine 22000 4351 2040 28624.5 152002 71272 3 Sulfa salazine 20000 2078 839 20479.5 101491 40946 Total - II 42000 6429 2879 49104.0 130935 58624

Worst Case - Any One Group 42000 8171 2879 51969 157236 55392



Table 2.10 Effluent Generated and Characteristics from Process – Stage Wise 1.Sulfanilamide

Stage Quantity (Kg/Day) Concentration (mg/l) Water Input TDS COD Total Effluent TDS COD

I 8000 1471.9 35.3 9504.1 154869 3712 II 34000 6699.6 695.0 42465.3 157766 16367

Total 42000 8171.5 730.3 51969.4 157236 14053 2.Sulfapyridine

Stage Quantity (Kg/Day) Concentration (mg/l) Water Input TDS COD Total Effluent TDS COD

I 22000 4351.0 2040.1 28624.5 152002 71272 Total 22000 4351.0 2040.1 28624.5 152002 71272

3.Sulfasalazine Stage Quantity (Kg/Day) Concentration (mg/l)

Water Input TDS COD Total Effluent TDS COD I 20000 2078.5 838.6 20479.5 101491 40946

Total 20000 2078.5 838.6 20479.5 101491 40946

2.4.1.1 Process Description and Technical Specification of Effluent Treatment System


total effluents are segregated into two streams High COD/ TDS and Low COD/ TDS

streams. The effluents are segregated stream wise based on the characteristics of effluents,

i.e., less than 15000 mg/l of TDS and COD are considered as low TDS effluents, while the

others are considered as high COD/TDS effluents.



Neutralization, Settling tank, Stripper, forced Evaporator followed by Agitated Thin Film

Dryer (ATFD). The organic distillate from the stripper is reused in process and aqueous

bottom from stripper is sent to forced evaporator followed by ATFD for evaporation. The

condensate from the forced evaporator and ATFD are sent to ETP (Biological). Salts from

ATFD are disposed to TSDF.




These effluents along with the condensate from forced evaporator and ATFD are treated in

primary treatment consisting of equalization, neutralization, and primary sedimentation

followed by secondary biological treatment consisting of aeration tank and clarifier.

The treated effluents after biological treatment are subjected to tertiary treatment in a

reverse osmosis system. Permeate from RO is reused for cooling tower and rejects are sent

to forced evaporator followed by ATFD. Sludge from various units of Biological treatment

are thickened in sludge handling system and sent to TSDF. Schematic diagram of effluent

treatment system is presented in Fig 2.4. Technical specifications of effluent treatment

system is presented in Table 2.11 and 2.12 respectively.



Fig

2.4

Sch

emat

ic D

iagr

am o

f Eff

luen

t Tre

atm

ent S

yste

m

Strip

per

Multip

le Effec

t Ev

apor

ator

Agita

ted Th

in

Film Dryer

Salts to TSD

F

Settlin

g tank

Equa

lization

& Ne

utraliz

ation

Org. Dist

illate

reus

ed in Pro

cess

Orga

nic

Distilla

te

High TD

S/CO

D

CondensateLo

w TDS &

COD

Scre

enCh

ambe

r

Slud

ge

Dryin

g Be

d

Oil

Skim

mer

Equa

lization

& Ne

utraliz

ation

Aeratio

nTa

nkClarifier

Holding

Tank

Filte

rs

Trea

ted W

ater

Stor

age Ta

nk

Filte

r Pre

ss

Slud

ge Cak

e to

TSDF

Doub

le

RO Pl

ant

Recy

cle W

ater

Colle

ction

Sump

To C

oolin

g To

wer

s

Rejects

Scru

bber Effluen

t, DM

/RO

Rejects

To M

EE

Slud

ge to

TSDF



Table 2.11 Technical Specifications of Effluent Treatment System S.No Description Unit Capacity

Existing Proposed Stripper for Process and Washings

1 Design Capacity KLD 56 2 Feed Rate Kg/hr 2166 3 Specific Gravity of Feed ≈ 1.2 4 Initial Feed COD PPM 55392 5 Feed Total Solid % 18.8 6 High Heating Temperature OC 80 7 High COD Condensate recovery LPH 90 8 Dry Saturated Steam requirement at 3.0Kg/cm2 (g) TPH 0.3 9 Cooling Water circulation rate for condenser m3/hr 10 10 Cooling Water Inlet Temperature OC 30 11 Cooling Water Outlet Temperature OC 33 12 Operating Condition

Forced Evaporator 1 Design Capacity KLD 15 45 2 Feed Rate Kg/hr 500 1576 3 Feed Concentration mg/l 150000 157236 4 Feed Temperature OC 80 5 Initial Solids % 20 18.8 6 Solids in Concentrate % 30 30 7 Concentrate Output Kg/hr 330 1030 8 Water Evaporation Rate Kg/hr 170 546 9 Designed Water Evaporation Rate Kg/hr 250 750 10 Dry Saturated Steam requirement at 5.0Kg/cm2 (g) TPH 0.2 0.6 11 Cooling Water Circulation Rate at 30 – 32OC m3/hr 40 120 12 Cooling Water Inlet Temperature OC 30 30 13 Cooling Water Outlet Temperature OC 33 33

Agitated Thin Film Dryer (ATFD) 1 Designed Capacity KLD 20 20 2 Designed Heat Transfer Area Sq.m 25 25 3 Feed Rate Kg/hr 680 680 4 Initial Feed Solid Content % 30 30 5 Final Moisture in Dry Bag-gable Product % 8 8 6 Water Evaporation Rate Kg/hr 450 450 7 Designed Water Evaporation Kg/hr 750 750 8 Solid Output in Bag-gable form at 5 – 10% moisture Kg/hr 230 230 9 Dry Saturated Steam requirement at 5.0Kg/cm2 (g) TPH 0.5 0.5 10 Cooling Water Circulation Rate at 30 – 32OC m3/hr 130 130 11 Cooling Water Inlet Temperature OC 30 30 12 Cooling Water Outlet Temperature OC 33 33



Table 2.12 Technical Specifications of Biological Treatment Plant Design inputs Data Flow from Evaporation : 42.0 KLD LTDS effluent : 50.0 KLD Total Flow : 92 KLD Design Capacity : 96 m3/day 1.Equalization Tank Peak Flow ( Designed) : 3.83 m3/hr Hydraulic retention time : 10 Hrs. at peak flow Volume of the tank : 40 m3 Tank dimensions : 4 x 4 x 2.5 L X B X H, m Air required for agitation : 0.01 m3/m2 min Total air required : 9.6 m3/hr Air blower required : 3HP m3/[email protected] 2) Primary clarifier Design quantity : 92 KLD Width : 2300 mm Length : 1300 mm Depth : 1200 mm No.of plates : 15 3) Biozone (Aeration)Tank Actual Flow : 92 KLD Length : 6900 mm Width : 2200 mm Diameter of Rotor : 1500 mm No of Rotors : 3 No.s 4) Secondary Clarifier : Width : 2300 mm Length : 1600 mm Depth : 1200 mm No.of plates : 22 5). Holding tank The flow from the each individual settling tank I,e the supernatant liquid is let into the respective Pre-Filtration Tank, which has a minimum 8 hours holding capacity. 6) MGF Capacity : 92 KLD Feed pump flow rate : 4.0 m3 Head : 30 m 8. ACF Capacity : 92 KLD Feed pump flow rate : 4.0 m3 Head : 30 M Rverse Osmosis Plant – I : 70 KL Rverse Osmosis Plant – I : 20 KL



2.4.2 Air Pollution

The manufacturing process consists of reaction, separation and purification. The reaction is

conducted in closed reactors, while the separation is conducted in centrifuge, filtration

equipment etc. The purification would be conducted in reactors or filtration equipment.

The transfer of materials will be through closed pipelines. Various sources of emissions are

identified from process operations. The usage of boiler for steam generation and DG sets

for emergency power back up also releases emissions.

2.4.2.1 Emissions from Utilities

It is proposed to establish 4 TPH coal fired boiler for proposed expansion and changing fuel of

existing 3TPH boiler from Oil fired to Coal fired and dismantling existing 1 TPH coal fired boiler

after expansion. The proposed air pollution control equipment for boiler is Multicone Cyclone

separators. DG sets shall be provided with stack heights based on the CPCB formula for

effective stack height. The emission rates of SO2, NOx and PM from each stack are presented

in Table 2.13.

Table 2.13 Emission Details of Pollutants from Stack S.No Stack Attached to Stack

Height (m)

Dia of stack

at top (m)

Temp. of exhaust

gases (0C)

Exit Velocity (m/sec)

Pollutant Emission Rate (g/sec)

PM SO2 NOx Existing

1* 1TPH Oil fired boiler

30 0.4 130 8 0.03 0.12 0.02

2** 3 TPH Coal Fired Boiler

30 0.6 160 12 0.15 0.4 0.21

3# 200KVA DG Set 3 0.1 200 10 0.003 0.08 0.01 4# 500 KVA DG set 7.5 0.2 160 15 0.004 0.16 0.03

Proposed 1 4TPH Coal Fired

Boiler 30 0.8 160 8.5 0.2 0.4 0.5

* Shall be dismantled after expansion ** Fuel changed from oil to coal. # DG sets will be used during load shut down by TSTRANSCO.



2.4.2.2 Emissions from Process



equipment etc. The purification would be conducted in reactors or filtration equipment.

The transfer of materials is through closed pipelines. Various sources of emissions are

identified;

2.4.2.3 Diffuse Emissions

Diffuse emissions are released from various operations of manufacturing like centrifuge,

drying, distillation, extraction etc. These emissions mainly contain volatile contents of the

material sent for processing. The emissions are normally passed through vent scrubber

before releasing into atmosphere to mitigate odor. The emissions from distillation are

passed through condensers, which mitigate odor.

2.4.2.4 Fugitive Emissions

Fugitive emissions are anticipated from equipment leakage and transfer spills. The

periodic maintenance program shall ensure integrity of equipment mitigating the

equipment leakage. The spills however shall be managed by adopting the spill

management scheme as mentioned in the respective MSDS. The fugitive emissions shall be

reduced by closed transfer and handling of all hazardous solvents and chemicals. The

ventilation system provided will reduce the health impact on employees by way of dilution

of work room air and also dispersion of contaminated air.

2.4.3 Solvent Use and Recycle (Terms of Reference No. B(1))

Solvents are used for extraction of products and as reaction medium. Solvents constitute

major consumable material of synthetic organic chemical manufacturing, mainly used as

reaction medium. The used solvents constitute major waste stream of synthetic organic

chemical manufacturing. Hence it is proposed to recycle the solvents by distillation for

reuse in process, thereby reducing the total solvent consumption in the plant and reducing

the waste quantity to be disposed. The distillation columns are mainly provided to remove



moisture and impurities from spent single solvents, and mixed solvents. The recycled single

solvents are reused in the process, while the mixed solvents are sold to end users.

Distillation process generates residues which are mainly organic in nature containing

significant calorific value, and can be sent to cement plants for co-incineration as fuel. The

total solvent balance product wise and stage wise is presented in Table 2.14.

Table 2.14 Total Solvent Balance Name of Product Name of Solvent Quantity (Kg/day)

Solvent Used

Recovered Fugitive Loss

To wastewater

Sulfapyridine Toluene 8900 8633 80.1 186.9 Pyridine 5350 5189.5 48.2 112.4

Sulfa salazine Acetic Acid 1710 1624.5 13.7 71.8

2.4.4 Solid Waste

Solid wastes are generated from the process, solvent distillation, wastewater treatment and

utilities. The effluent treatment system generates, stripper distillate, ATFD salts and ETP

sludge. The process operations generate process residue, activated carbon and inorganic

residue. The utilities i.e., coal fired boiler generates ash while DG sets generate waste oil and

used batteries. All the wastes except coal ash are considered hazardous. The other non

hazardous wastes are container, packing material, empty drums etc. The containers and

drums are detoxified before disposing to authorized buyers. The hazardous wastes of

process residue and activated carbon are sent cement plants for co-incineration, thereby

reducing the load on TSDF facility and consumption of non renewable resource of coal in

cement plant kilns, stripper distillate is reused in process. The inorganic wastes, salts from

ATFD, and ETP sludge are sent to TSDF facility located at Dundigal, Ranga Reddy district.

The waste oil and used batteries are sold to authorized recyclers. Coal ash is sold to brick

manufacturers in the local area. The quantity of solid waste generated in the plant and the

disposal practice is presented in Table 2.15.



Table 2.15 Total Solid Waste Generated and Mode of Disposal

S.No Description Units Quantity Mode of Treatment/Disposal Permitted After

Expansion 1 Ash from Boiler TPD 5.44 18.74 Sold to Brick manufactures

and cement plants 2 Organic residue TPD 0.86 Sent to TDSF/Cement Plants

for Co-incineration 3 Stripper Distillate KLD 2 Reused in process 4 Spent Carbon Kg/day 53 140 Sent to Cement Industries for

Co-incineration. 5 Inorganic

Residue TPD 0.582 Sent to TSDF

6 Evaporation salts TPD 1.145 9.77 Sent to TSDF 7 ETP Sludge Kg/

month 280 Sent to TSDF

8 Detoxified containers

No.s/ Month

10 300 Sold to authorized vendors

9 Waste oil Lit/ Month

5 15 Sent to Authorized Recyclers

10 Used batteries No.s/Yr 10 15 Sent to Authorized Recyclers

2.4.5 Noise Pollution

Noise is anticipated from motors, compressors and DG set. The DG shall be kept in a

separate enclosed room with acoustic enclosure. The motors and compressors shall be

provided with guards and shall be mounted adequately to ensure the reduction of noise and

vibration. The employees working in noise generating areas shall be provided with

earmuffs. The employees shall be trained in the mitigation measures and personal

protection measures to be taken to avoid noise related health impacts.



CHAPTER 3.0 BASELINE ENVIRONMENTAL STATUS

3.1 Introduction

Collection of base line data is an integral aspect of the preparation of Environmental

Impact Assessment Report. Baseline data reflects the present status of environment

before initiation of any activity of proposed project. The possible effects due to

proposed project of Virchow Drugs Limited are estimated and superimposed on the

compiled baseline data subsequently to assess environmental impacts.

The study was conducted in the impact area; 10 km radius area surrounding the

project site, during February - May 2016. Studies were undertaken to generate

baseline data of Micrometeorology, Ambient air quality, water quality, noise levels,

flora and fauna, land use, soil quality, and socio-economic status of the community.

3.2 Land Environment

Land and soil constitute the basic components of the physical environment. The

location of an industrial project may cause changes in land, land use, soil and

denudational processes in different intensities contingent on sptial proximity of the

activity and receptors. Land and soil may get altered within the vicinity of 5 km

radius and to a lesser extent upto 10 km radial distance due to the development of

present industrial project and Bonthapally IDA.

3.2.1 Physiography


Medak District, Telangana. The site is situated at intersection of 78021’15.06” (E)

and latitude 17039’24.70” (N). The site is surrounded by road connecting Jinnaram

and Bonthappay in north direction, SSI Company in south direction, M/s. Samkrg

Pistons and Rings Ltd., in east direction and open land in west direction. The

nearest habitation from the site is bonthapally at a distance of 1.2 Km in northeast

direction. The main approach road is Hyderabad – Narsapur passing at a distance of

2 km in east direction. The nearest railway station is Medchal at a distance of 12.87

km in southeast direction and the nearest airport is located at a distance of 48 km in

southeast direction. Medchal town is located at a distance of 12.8 km in southeast

direction.There are no major water bodies within the study area. Bonthapalle RF at a



distance of 0.4 Km in northwest, Jinnawaram RF at a distance of 6.5 Km in

southwest, Mangapet RF at a distance of 5 Km in east, Royyapalli RF at a distance of

7 Km in east, Wailal RF at a distance of 8 Km in south, Dundigal RF at a distance of

8.5 Km in southeast, Nagawaram RF at a distance of 8 Km in northwest, Mambapur

RF at a distance of 6.5 Km in northwest, Nallavalli RF at a distance of 8 Km in

northwest, Pottaguda RF at a distance of 9 Km in southwest directions respectively.

There are no ecologically sensitive areas like national parks, and sanctuaries within

10 km radius of the site. The slope of the region is from southeast to northwest

direction. The area has mainly single crop agriculture lands irrigated either by tube

wells and or rainfed.The site location photographs are presented in Figure 3.1.

Figure 3.1 Site Photographs of M/s. Virchow Drugs Limited (Terms of Reference No. 4(vii)

3.2.2 Geology (Terms of Reference No. 4(x)

The area under investigation forms a part of Peninsular Granitic / Gneissic complex

with soil cover ranging from 0 – 3 M followed by 15 – 18 M of weathered mantle and

with fractured and fissured zone upto 45 – 50 M over the massive granitic body with

exception to few areas where deep seated fracture intensity observed at few bore

wells drilled a depth beyond 80 M BGL.

The stratigraphic classification is as follows : Age Rock Type Sub Recent – Recent Soil Archeans Granites, Gneisses & Quartz Reefs

3.2.3 Hydrogeology (Terms of Reference No. 4(x)

The entire study area is covered by hard rock except for 35% of the area. Ground

water occurs under unconfined to confined conditions in both hard rock (Archean



and Deccan traps) and soft (Alluvial) formations. The common ground water

abstraction structures are dug wells, dug-cum-bore wells and bore wells and their

yields mainly depending on the recharge conditions in the area. The entire study

area is underlain by consolidated rocks. Yield potential of the aquifers in thee

consolidated rocks vary widely. Due to indiscriminate drilling of bore wells, the

yields have fallen drastically leading to failure of wells.

Ground water is one of the important sources both for domestic, irrigation and

Industrial purposes in the study area and is being exploited through large diameter

dug wells, bore wells and dug-cum bore wells. In the Archeans, ground water occurs

under phreatic conditions in shallow weathered mantle and under semi confined

conditions in the fractured zones. The depth of weathering varies between 5.5 and 15

m bgl. The domestic dug wells are often circular in shape ranging in diameter from

1.1 to 3.0 m, while the irrigation wells are either rectangular or square in shape with

size ranging from 2.7 x 4.5 m to 20 x 10.m without any lining. The circular irrigation

wells range in diameter from 4.5 to 12.5 m. Total depth of domestic wells varies from

8 to 16 meters below ground levels (m.bgl) and the depth to water level varies from

4.5 to 15 m bgl. Extension bores of 102 mm dia are drilled at the bottom of the dug

well down to a depth of 20 to 30 m to improve the yield of the irrigation wells which

are called as dug cum bore wells. The yield of such wells ranges from 0.17 to 0.3

litres per second (lps). The yields of irrigation dug wells range between 40 and 135

KLD in majority of the cas es and in a few it exceeds 135 KLD. The principle mode of

withdrawal from these wells is through centrifugal pumps with 3 to 5 HP motors are

capable of irrigating 0.4 to 2 Ha of land sustaining to 1 to 5 hrs of pumping in a day.

On an average, it takes 24 hours for water levels to recoup. Due to scanty rainfall and

ever increasing population, majority of the dug wells/dug-cum bore wells have

gone dry. At present, maximum irrigation needs are met through bore wells. Bore

wells of 102 mm are common in the study area and utilized for domestic supply. The

depth of these bore wells ranges between 20 to 45 m yielding 1.5 to 75 KLD. In

weathered granite and alluvium, the transmissivity values ranges from 100 to 150

sq.m/day and the specific capacity ranges from 0.005 to 0.16 KLD per unit cross-

section. The rise in water levels between pre-monsoon and post-monsoon ranges



between 0.03 to 16.26 m.

3.2.4 Soils

Soil 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 such as parent

materials, climate, organisms and physico-chemical action of wind, water and

sunlight, all acting over a period of time. Soil differs from the parent materials in the

morphological, physical, chemical and biological properties. Also soil differs among

them in some or all the genetic or environmental factors, therefore, some soils are

yellow, some are black, and some are coarse textured. They serve as a reservoir of

nutrients for plants and crop and also provide mechanical anchorage and favorable

tilth.

The Soil characteristics include both physical and chemical parameters. M/s. Team

Labs and Consultants field team carried out soil survey to assess the soil

characteristics of the study area. The Base map of the study area is shown in Figure

3.2 and the land use and land cover map of the study are shown in Figure 3.3. It may

be noted that the land use land cover map reflects predominant agriculture nature of

the impact area, and also its dependence on tanks for irrigation. Representative soil

sampling was done at several important locations and these locations are shown in

Figure 3.4. Analytical data of soil samples is presented in Table 3.1.



Figu

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.2 B

ase

map

of t

he s

tudy

are

a



Figu

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.3 L

and

use

and

land

cov

er o

f the

stu

dy a

rea

(Ter

ms

of R

efer

ence

No.

4(ix

) & 5

(ii))



Figu

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.4 S

oil S

ampl

ing

Loca

tions



Table 3.1 Soil Analysis Data (Terms of Reference No. 6(viii) Parameter Unit S-1 S-2 S-3 S-4 S-5 S-6 S-7 pH 7.2 6.83 7.56 7.87 7.64 7.41 5.8 Electrical Conductivity (EC) mmhos/cm 671 8260 320 426 526 805 250 Bulk Density g/cc 1.57 1.25 1.33 1.33 1.54 1.54 1.54 Cation-Exchange Capacity (CEC) meq/ 100 gm 217.26 164 198 151 208 235 168 Infiltration rate mm/ hour 16.32 15 16 25 24 17 21 Porosity % 42.84 53 50 50 42 42 42 Water Holding Capacity (W.H.C) % 15.1572 20.95 16.94 15.89 8.66 30.64 30.57 Moisture % 13.20 17.32 14.49 13.71 7.97 23.45 11.95 Organic Matter % 2.244 2.7 0.2 1.5 0.6 1.3 0.8 Carbonates % Nil Nil Nil Nil Nil Nil Nil Sand % 44.88 54 50 59 60 40 54 Silt % 31.62 36 34 24 20 48 28 Clay % 25.5 10 16 17 20 12 18 Organic Carbon % 1.31 1.6 0.1 0.9 0.3 0.8 0.5 Nitrogen (as N) % 0.01 0.210 0.012 0.012 0.018 0.017 0.011 Carbon / Nitrogen Ration (C/N) 163.2 7.62 8.33 75.00 16.67 47.06 45.45 Phosphorus (as P) mg/kg 846.6 844 608 843 997 675 791 Potassium (as K+) mg/kg 306 1118 574 739 209 153 127 Sodium (as Na+) mg/kg 7813.2 1189 124 120 100 105 71 Calcium (as Ca2+) mg/kg 224.4 180 60 60 40 80 80 Magnesium (as Mg2+) mg/kg 111.18 36 12 24 24 61 12 Calcium/Magnesium ratio 2.06 4.94 4.94 2.47 1.65 1.32 6.58 Base Saturation 170.71 55.26 11.92 18 6.10 6.39 6.47 Sodium Absorption Ratio (SAR) 122.28 22.60 4.08 3.70 3.56 2.54 2.06 Chlorides (as Cl-) mg/kg 362.1 425 177 71 106 71 106 Sulphates (as SO42-) mg/kg 37.74 345 105 142 52 40 65 Aluminium (as Al) mg/kg <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 Arsenic (as As) mg/kg <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 Boron (as B) mg/kg <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 Cadmium (as Cd) mg/kg <0.002 <0.002 <0.002 0.01 0.01 0.003 0.01 Chromium ( as Cr) mg/kg 0.255 0.18 0.18 0.08 0.08 0.31 0.15



Parameter Unit S-1 S-2 S-3 S-4 S-5 S-6 S-7 Copper (as Cu) mg/kg 0.14 0.1 0.1 0.04 0.0 0.7 0.0 Iron (as Fe) mg/kg 69.36 53.0 57.0 47.0 47.0 60.0 50.0 Lead (as Pb) mg/kg 0.357 0.20 0.31 0.24 0.17 0.13 0.20 Manganese (as Mn) mg/kg 1.02 1.05 3.17 0.68 0.88 5.43 0.80 Mercury (as Hg) mg/kg <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 Nickel (as Ni) mg/kg 0.18 0.11 0.19 0.07 0.06 0.39 0.13 Selenium (as Se) mg/kg <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 Silver (as Ag) mg/kg 0.45 0.10 0.09 0.11 0.12 0.11 0.08 Zinc (as Zn) mg/kg 0.4 0.36 0.36 0.19 0.11 0.55 0.14 Texture loam Sandy

loam loam Sandy

loam Sandy loam

loam Sandy loam

S1-Site, S2-Bontha pally, S3-Gummadidala, S4- Antaram, S5 Jinnaram, S6- Kanukunta & S7- Srirangaram.



The test results of soil samples collected in the impact area are interpreted referring

to the book; “Interpreting soil test results”. The reference tables are presented in

Table 3.2. The pH of soil samples ranges from moderately acid to mildly alkaline.

The cation exchange capacity of the soils is very high (seven Samples), contributed

mainly by sodium exchangeable ions. The level of nitrogen of the samples is very

low to medium while the potassium levels are low to excessive.The base saturation

of the samples is predominantly very strongly leached (four Samples), strongly

leahed (one sample), weakly Leached (one sample) and very weakly Leached (one

sample). The calcium magnesium ratio of the samples reflects calcium is low in four

samples, balanced in two samples and magnesium is low in one sample. Bulk

density of soil of impact varies from 1.33 – 1.44 g/cc among loamy soils, and 1.25 to

1.54 g/cc among sandy loam soils. The porosity values range from 42 – 50 % among

loamy soils, and 42 -53 % among sandy loam soils. Soil texture is predominantly

sandy Loam and Loamy.

Table 3.2 Soil Test Results – Reference Tables General interpretation of pH measured Rating for Cation exchange Capacity

pH Range Classification CEC (Cmol)+)/kg <4.5 Extremely Acidic Very low <6 * 4.51 -5.0 Very Strong Acidic Low 6-12 5.1-5.5 Strong Acid Moderate 12-25 5.6- 6.0 Moderately Acid High 25-40 6.1-6.5 Slightly acid Very High >40 6.6-7.3 Neutral Source: Metson (1961)

* Soils with CEC less than three are often low in fertility and susceptible to soil acidification.

7.4-7.8 Mildily Alkaline 7.9 -8.4 Moderately Alkaline 8.5-9.0 Strongly Alkaline >9.0 Very Strongly Alkaline

Source: Bruce and Rayment (1982). Ca/mg Ratio Base Saturation as a criterion of leaching

Description Range (%BS) Rating <1 Ca Deficient 70-100 Very Weakly Leached 1-4 Ca (Low) 50-70 Weakly Leached 4-6 Balanced 30-50 Moderately Leached 6-10 Mg (Low) 15-30 Strongly Leached >10 Mg deficient 0-15 Very Strongly Leached Source: Eckert (1987) Source: Metson (1961)

Rating of Total Nitrogen Extractable Potassium (K) Rating (% by W) Description K <0.05 Very low low <150 ppm* (< 0.4 meq/100 g soil) 0.05-0.15 Low medium 150–250 ppm (0.4–0.6 meq/100 g soil) 0.15-0.25 Modium high 250–800 ppm (0.6–2.0 meq/100 g soil) 0.25-0.50 High excessive >800 ppm (>2.0 meq/100 g soil) >0.5 Very High Source: Abbott (1989) Source: Bruce and Rayment (1982)



3.3 Water Environment

The industrial development of any region is contingent on the availability of

sufficient water resources, as most of the process industries would require water for

process or cooling purposes. The potential for exploitation of ground water

resources increases as development of new projects increases in industrial and

agricultural areas. With the increasing industrialization and urbanization the

possibilities of contamination of surface water and ground water sources are rapidly

increasing. The water resources in the area broadly fall into following categories:

1. Surface Water resources: Streams and ponds, etc. 2. Ground Water resources: Accumulation in deeper strata of ground.

3.3.1 Surface Water Resources

There are a few water surface bodies like natural lakes existing in the study area.

These tanks are located in southwest and southeast directions. The drainga map of

the Study area is presented in Figure 3.5.

3.3.1.1 Surface Water Quality

In order to have an idea of quality of water flowing in the region, representative

water samples were observed to be dry.

3.3.2 Ground Water Resources

Ground water is the accumulation of water below the ground surface, caused by

rainfall and its subsequent percolation through pores and crevices. Percolated water

accumulates till it reaches impervious strata consisting of confined clay or confined

rocks. Occurrence of ground water is controlled by landform, structure and

lithology. Ground water abstraction is by means of dug wells, dug cum driven wells,

and bore wells and open alluvial. Ground water resources are ample in the study

area. Every village has a number of traditional wells large and small. The state

authorities have also provided tube wells fitted with hand pump for the drinking

water requirement of villages in the study area. Presently the drinking water needs

are mostly met from the ground water resources.



3.3.2.1 Quality of Ground Water (Terms of Reference No: 29)

The quality of ground water occurring in the geological formations in the study area

is generally good in most of the areas. The representative samples are collected

from various dug wells and bore wells in the study area. The analytical results of

water samples drawn from various locations in the study area are presented in

Table 3.4. The map showing the locations of sample collection (Figure 3.6) is also

presented. Whereas Total dissolved solids are 356-3876 mg/l, which is contributed

by sodium and chlorides. Iron, Calcium are may be attributed to local geology.

Piper trilinear diagram were used in the study as to classify the hydro-chemical

facies present. The analyses were converted from parts per million to equalenfs per

milion and the percentages of equivalents were computed and were plotted.

Trilinear diagram for ground water is presented in Figure 3.7. The concentrations or

percentages of the constituents selected as being most informative were: Sodium,

Magnesium, calcium and Potassium as-percentage of the total cations, in equivalents

per million (Cation facies); bicarbonate and carbonate (where present) as percentage

of total anions, in equivalents per million (anion facies), sum of determined

constituents in equivalents per million; concentration of chloride ion, in parts per

million; and concentration of the bicarbonate ion, on parts per million.

Piper trilinear diagrams for ground waters show that most of the water samples are

primarily of the magnesium carbonates and bi-carbonates.

Water hardness is caused primarily by the presence of cations such as calcium and

magnesium and anions such as carbonate, bicarbonate, chloride and sulfate in water.

Water hardness has no known adverse effects; however, some evidence indicates its

role in heart disease. Hard water is unsuitable for domestic use. In this region, the

total hardness varies between 140-1840 ppm. According to Sawyer and McCarty’s

classification for hardness, 5 samples fall under Very Hard class.



Table 3.3 Locations of Ground water Sampling (Terms of Reference No. 6(vi) S. No Location Name Direction Form

site Distance From

Site (Km) GW-01. Plant site - - GW -02. Bontapalli SW 0.6 GW -03. Gummadidala NW 1.8 GW -04. Annaram S 3.5 GW -05. Jinnaram SW 3.8 GW -06. Kanukunta NE 4.7 GW -07. Srirangaram SE 5.3



Figu

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.5 D

rain

age

Patte

rn p

f the

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rea

(Ter

ms

of R

efer

ence

No.

4(x

i)



Figu

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.6 W

ater

Sam

plin

g Lo

catio

ns



Table 3.4 Water Analysis Data –Ground Water

Parameters GW-1 GW-2 GW-3 GW-4 GW-5 GW-6 GW-7 Units Method of Analysis IS 10500:2012 Standard

Temperature 32 33 32 32 31 32 31 oC IS:3025 part 09:2002 Colour Nil Nil Nil Nil 5 12 8 Hazen IS:3025 part 04:1983 5 Turbidity Nil 0.4 0.1 0.1 13.6 36.5 139 NTU IS:3025 part 10:1984 5 pH 6.8 7.27 7.18 7.02 7.1 7.26 6.85 IS:3025 part 11:1983 6.5-8.5 Total Solids 359 4282 857 390 834 1025 1065 mg/l IS:3025 part 15:2003 Ns Total Dissolved Solids 354 3876 853 386 816 998 962 mg/l IS:3025 part 16:2006 500 Total Suspended Solids 5 406 4 4 18 27 103 mg/l IS:3025 part 17:1999 100 Total Hardness (as CaCO3) 199 1840 605 140 470 585 505 mg/l IS:3025 part 21:2002 200 Calcium (as Ca2+) 55.7 520 146 38 130 148 120 mg/l IS:3025 part 40:2004 75 Magnesium (as Mg2+) 15 131 58 11 35 52 50 mg/l IS:3025 part 46:2003 30 Sodium (as Na) 50 245 87 74 111 191 168 mg/l IS:3025 part 45:2003 Ns Sodium Absorption Ratio (SAR)

1.7 2.7 2 3.0 2.4 3.8 3.6 100

Potassium (as K+) 8.4 9 1.6 1.1 17 1.6 6 mg/l IS:3025 part 45:2003 Ns Carbonate (as CO3) Nil Nil Nil Nil Nil Nil Nil mg/l IS:3025 part 51:2001 Ns Bi carbonate (as HCO3-) 55 549 518 305 488 550 366 mg/l IS:3025 part 51:2001 Ns Alkalinity (as CaCo3) 55 549 518 305 488 550 366 mg/l IS:3025 part 23:2006 200 Chloride (as Cl-) 134 1021 174 32 220 255 354 mg/l IS:3025 part 32:1988 250 Sulphate (as SO42-) 51 422 72 25 48 106 67 mg/l IS:3025 part 24:1986 200 Nitrate Nitrogen (as NO3-) 1.2 1.70 3.0 0.03 2.30 0.90 0.3 mg/l IS:3025 part 34:1999 45 Silica (as SiO2) 0.5 0.8 1.6 1.10 0.30 0.6 1.1 mg/l IS:3025 part 35:2003 Ns Fluoride (as F -) 0.3 0.40 0.30 0.20 0.25 0.30 0.20 mg/l IS:3025 part 60:2008 1.0 Residual, Free Chlorine Nil Nil Nil Nil Nil Nil Nil mg/l IS:3025 part 26:2004 0.20 Cyanide (as CN) <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 <0.02 mg/l IS:3025 part 27:1998 0.05 Aluminium (as Al) <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 mg/l IS:3025 part 55:2003 0.03 Arsenic (as As) <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 mg/l IS:3025 part 37:1999 0.01 Boron (as B) <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 mg/l IS:3025 part 57:2005 0.50 Cadmium (as Cd) <0.002 <0.002 <0.002 <0.002 <0.002 <0.002 <0.002 mg/l IS:3025 part 41:2003 0.003 Total Chromium (as Cr) 0.01 0.01 0.01 0.01 0.02 <0.02 <0.02 mg/l IS:3025 part 52:2003 0.05



Parameters GW-1 GW-2 GW-3 GW-4 GW-5 GW-6 GW-7 Units Method of Analysis IS 10500:2012 Standard

Hexavalent Chromium (as Cr6+)

<0.03 <0.03 <0.03 <0.03 <0.03 <0.03 <0.03 mg/l IS:3025 part 52:2003 0.05

Copper (as Cu) 0.04 <0.01 <0.01 <0.01 0.01 0.03 0.01 mg/l IS:3025 part 42:2004 0.05 Iron (as Fe) 6.20 1.20 0.94 1.30 6.60 27.00 56.00 mg/l IS:3025 part 53:2003 0.30 Lead (as Pb) 0.41 0.39 0.38 0.33 0.35 0.41 0.34 mg/l IS:3025 part 47:2003 0.01 Manganese (as Mn) 0.11 0.06 0.03 0.03 0.05 0.09 0.09 mg/l IS:3025 part 59:2006 0.10 Mercury (as Hg) <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 mg/l IS:3025 part 48:2003 0.001 Nickel (as Ni) 0.01 0.01 0.01 0.01 0.01 0.07 0.01 mg/l IS:3025 part 54:2003 0.02 Selenium (as Se) <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 <0.001 mg/l IS:3025 part 56:2003 0.01 Zinc (as Zn) <0.005 0.27 <0.005 <0.005 0.48 2.90 0.17 mg/l IS:3025 part 49:2003 5.0

GW1-Site, GW2-Bonthapally, GW3-Gummadidala, GW4- Annaram, GW5- Jinnaram, GW6- Kanukunta & GW7- Srirangaram. Note: All values are expressed in mg/l except pH, A-Absent.



Figure 3.7 Piper Trilinear Diagram for Ground water

3.4 Air Environment

3.4.1 Meterology

Micro meterological studies are simultaneously conducted with the air quality

monitoring. Methodology plays a vital role in effecting the dispersion of pollutants,

once discharged into the atmosphere, their transport, dispersion and diffusion into

the environment. The meteorological data is very useful for interpretation of the

baseline information and for model study of air quality impacts also. Since

meteorological data show wide fluctuations with time, meaningful interpretation

can only be drawn from long term and reliable data. Such source of data is the India

Meteorological Department (IMD) that maintains a network of meteorological

stations at several important locations. The data recorded for nearest IMD station at

Medak is summarized for the period 1961 to 1990 and the same is presented in Table

3.5.



Tabl

e 3.

5 N

orm

al C

limat

rolo

gica

l Dat

a





3.4.2 Meteorological Station at Industry Site (Terms of Reference No. 6(i)

The micro meteorological data at the industry site is collected simultaneously with

the ambient air quality monitoring. The station was installed at height of 10 meters

above the ground level and the same is located in such a way that there are no

obstructions facilitating free flow of wind. Wind speed, wind direction, humidity

and temperature are recorded on hourly basis in the study period. Salient features of

micro meteorological data collected are as follows:

1. Wind Direction and Speed:

The hourly wind speed and wind direction observations are computed during

various seasons of study period and the same are presented in Table 3.6 and the

wind rose diagrams are presented in Figure 3.8. The following observations can be

made from the collected data;

• Calm period is observed to be 32.74 % during the time of monitoring.

• The predominant wind direction is southeast.

• Other than predominant wind directions wind was blowing in east- Southeast and

East.

• Mostly the wind speeds are observed to be in the range of 1 – 5 and 10-15. The

maximum and minimum temperature and relative humidity and total seasonal

rainfall are summarized in below. The salient features are discussed in brief as

follows.

2. Temperature:

(a) Maximum: 43.2 0C (b) Minimum: 20.7 0C (c) Average: 28.02 0C

3. Humidity:

The daily relative humidity values are observed to range between 18 - 65%.

4. Rain Fall:

(a) Maximum: 8.2 mm (b) Minimum: 0 mm



Table 3.6 Frequency Distribution of Wind Speeds and Wind Directions

Wind Direction Wind Speed in kmph Calm 1 - 5 5-10 10-15 >15 Total

N 0.50 0.23 0.72 NNE 0.32 0.32 0.14 0.77 NE 1.13 1.09 0.59 2.81 ENE 2.13 0.45 0.36 2.99 E 3.31 3.67 1.72 0.23 8.92 ESE 3.35 3.85 2.04 0.05 9.28 SE 6.25 4.71 1.45 0.14 12.55 SSE 3.17 1.99 0.41 5.57 S 3.40 1.22 0.54 5.16 SSW 2.49 2.22 0.82 0.05 5.57 SW 2.36 2.22 0.45 5.03 WSW 1.72 0.91 0.41 3.03 W 1.36 1.13 0.45 0.05 2.99 WNW 0.59 0.59 0.32 1.49 NW NNW 0.23 0.36 0.05 0.63 CALM 32.47 32.47 Total 32.47 32.29 24.95 9.74 0.54 100.00



WRPLOT View - Lakes Environmental Software

WIND ROSE PLOT:

COMMENTS:

MODELER:

Team Labs and Consultanst, Hyderabad.

PROJECT NO.:

NORTH

SOUTH

WEST EAST

3%

6%

9%

12%

15%

WIND SPEED (m/s)

>= 4.2

2.8 - 4.2

1.4 - 2.8

0.3 - 1.4

Calms: 32.47%

TOTAL COUNT:

2208 hrs.

CALM WINDS:

32.47%

DATA PERIOD:

Start Date: 3/1/2013 - 00:00End Date: 5/31/2013 - 23:00

AVG. WIND SPEED:

0.98 m/s

DISPLAY:

Wind SpeedDirection (blowing from)

Figure 3.8 Wind Rose Diagram at Site



3.4.3 Ambient Air Quality

Air pollution means the presence in the outdoor atmosphere of one or more

contaminants or combinations thereof in such quantities and of such duration as are

or may tend to be injurious to human, plant or animal life or property. Air

pollutants include smoke, vapors, soot, fumes, gases, mist, odors, particulate matter,

radioactive material or noxious chemicals. With upcoming industrial activity a range

of different pollutants are released into the atmosphere that are dispersed and have a

significant impact on neighborhood air environment. Thus collection of base line

data of air environment occupies a predominant role in the impact assessment

statement. The ambient air quality status across the study zone forms basis for

prediction of the impacts due to the project.

The project is located at Bonthapally IDA, Jinnaram Mandal in Medak District. The

data required for assessing air quality impacts in and around neighborhood is

achieved by designing such a network, which encompasses micro meteorological

conditions, quantity and quality of emissions, locations, duration,

resources/monitoring technology and operational criteria. The optimal scheme for

air quality monitoring should consider all the above factors.

3.4.4 Scope of Field Study

The scope of baseline status of the ambient air quality can be assessed through a

well-designed ambient air quality stations network. An intensive ambient air quality

monitoring of the study area consisting of 10 km radius with the proposed Plant site

as the center point was carried out during the study period. The ambient air quality

was monitored at seven locations spread over entire study area. Figure 3.9 presents

the locations of seven ambient air quality-monitoring stations. At each sampling

station monitoring was carried out for 24 hours in a day for 2 days a week, and for

three months. The major air pollutants monitored on 24 hourly basis are, Particulate

Matter (Size Less than 10µm) or PM10 µg/m3, Particulate Matter (Size Less than

2.5µm) or PM2.5 µg/m3, Sulfur dioxide and Oxides of Nitrogen. Sampling and

analysis of the above variables is according to the guidelines of Central Pollution

Control Board. National Ambient Air Qualiy Standards is presented in Table 3.7.



Table 3.7 National Ambient Air Quality Standards Pollutant Time

Weighted Average

Concentration in Ambient Air

Industrial, Residential, Rural and

Other Area

Ecological Sensitive Area (Notified by

Central Government)

Methods of Measurement

Sulphur Dioxide (SO2)

Annual* 24 Hours**

50

80

20

80

Improved west and Gaeke Ultraviolet fluorescence

Nitrogen Dioxide (NO2)

Annual* 24 Hours**

40

80

30

80

Modified Jacob & Hochheiser (Nn-Arsenite) Chemiluminescence

Particulate Matter (Size Less than 10µm) or PM10

Annual* 24 Hours**

60

100

60

100

Gravimetic TOEM Beta Attenuation

Particulate Matter (Size Less than 2.5µm) or PM2.5

Annual* 24 Hours**

40

60

40

60


Ozone (O3) 8 hours** 1 hour**

100

180

100

180

UV Photometric Chemilminescence Chemical Method

Lead (Pb) Annual* 24 hours**

0.50

1.0

0.50

1.0

AAS /ICP method after sampling on EPM 2000 or equivalent filter paper ED - XRF using Teflon filter.

Carbon Monoxide (CO)

8 hours** 1 hour**

02

04

02

04

Non Dispersive Infra Red (NDIR) Spectroscopy

Ammonia (NH3) Annual* 24 hours**

100 400

100 400

Chemilminescence Indophenol blue method

Benzene (C6H6) Annual* 05 05 Gas Chromotography based continuous analyzer Absorption and Desorption followed by GC analysis

Benzo (o) Pyrene(BaP) – Particulate Phase only,

Annual* 01 01 Solvent extraction followed by HPLC/GC analysis

Arsenic (As), Annual* 06 06 AAS/ICP method after sampling on EPM 2000 or equivalent filter paper

Nickel (Ni), Annual* 20 20 AAS/ICP method after sampling on EPM 2000 or equivalent filter paper

G.S.No.826 (E) dated 16th November, 2009. Vide letter no. F. No. Q-15017/43/2007-CPW *Annual Arithmetic mean of minimum 104 measurements in a year at a particular site taken twice a week 24 hourly at uniform interval. **24 hourly/8/1 hourly monitored values as applicable, shall be complied with 98 percent of the time in a year.2% of time they may be exceeded the limits but not on two consecutive days of monitoring.



3.4.5 Description of Sampling Locations

The location of ambient air quality stations is contingent on the meteorological status

of the area. Hence the micro meteorological data was collected before initiating the

ambient air quality monitoring. Table 3.8 presents the ambient air quality locations

and their distances and directions from the plant site.

Table 3.8 Locations of Ambient Air Quality Monitoring Stations

S. No Location Direction w.r.t Plant Distance from plant site (KM)

1. Plant site - - 2. Bontapalli SW 0.6 3. Gummadidala NW 1.8 4. Annaram S 3.5 5. Jinnaram SW 3.8 6. Kanukunta NE 4.7 7. Srirangaram SE 5.3



Figu

re 3

.9 A

mbi

ent A

ir Q

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y M

onito

ring

Loc

atio

ns



3.4.6 Ambient Air Quality Status ((Terms of Reference No. 6(ii) & B(3))

The existing baseline levels with respect to Particulate Matter (Size Less than 10µm)

or PM10 µg/m3, Particulate Matter (Size Less than 2.5 µg/m3) or PM2.5 µg/m3,

Sulphur dioxide and oxides of nitrogen at 6 locations are presented in Table 3.9 The

parameters monitored at the site show the following variations; the voc and HC

values are observed below detectable limits, the other parameters of NAAQ

standards are found to be below detectable limits except for PM10, PM 2.5, SO2 and

NOx. It may be observed that the all parameters at all stations are well within the

limits prescribed by Central Pollution Control Board.

Table 3.9 Ambient Air Quality Status Sampling Time: 24 Hrs Unit: µg/m3

Pollutant Maximum Minimum Mean 98 Percentile AAQ-1) Location: Site PM10 58 46 52 58 PM2.5 18 12 15 18 SO2 20 8 14 19 NOx 18 9 12.38 17 VOC in PPM 12.2 4.8 8.5 10.8 AAQ-2) Location: Bontapalli PM10 48 36 40.65 47 PM2.5 16 10 12.81 15 SO2 12 7 8.73 11 NOx 15 10 12.08 15 VOC in PPM 1.5 0.3 0.9 1.2 AAQ-3) Location: Gummadidala PM10 46 31 38.35 44 PM2.5 16 10 12.65 16 SO2 12 9 8.15 10 NOx 14 9 11.58 14 VOC in PPM 0.6 0.3 0.4 0.5 AAQ-4) Location: Annaram PM10 53 37 43.38 51 PM2.5 19 11 13.58 19 SO2 13 9 9.27 12 NOx 16 9 12.04 15 VOC in PPM BDL BDL BDL BDL AAQ-5) Location: Jinnaram PM10 42 24 33.50 38 PM2.5 16 10 12.81 16 SO2 12 9 8.54 11 NOx 14 9 11.58 14 VOC in PPM BDL BDL BDL BDL AAQ-6) Location: Kanukunta PM10 41 24 31.35 39 PM2.5 15 10 12.81 14



SO2 11 9 7.77 10 NOx 14 9 11.35 14 VOC in PPM 0.3 0.1 0.2 0.2 AAQ-7) Location: Srirangavaram PM10 43 23 35.00 41 PM2.5 14 10 11.58 14 SO2 11 9 7.23 10 NOx 14 9 11.04 14 VOC in PPM BDL BDL BDL BDL

VOC concentration measured as Isobutylene euivalent.

3.4.6.1 Analysis of Poly-Aromatic Hydrocarbons (PAH) in RSPM

Over the past years PAH’s have been found to be ubiquitous constituents of urban

airborne particles and have become a major health concern mainly due to their well-

known carcinogenic and mutagenic properties. PAH’s formed during incomplete

combustion of organic materials such as fossil fuels, coke and wood. Residence time

and removal mechanisms of PAHs in the atmosphere depend on their distribution

among the particle size fractions.

PAH’s emitted from combustion sources and thus emitted to atmosphere in gas

phase or in fine particles. After the entrance to atmosphere they are cold and they

unite or adsorbed into small particles. Those processes lead PAH’s in higher

concentrations to fine particles. The other parameters of CO, Ozone, Ammonia,

Nickel, Arsenic and Lead are found to be below detectable limits. The volatile

organic compound concentrations in the ambient air, and the values are observed to

be ranging from 0.1 to 12.2 ppm at plant premies and near by villages rest of villages

are found to be BDL.

Table 3.10 Chemical composition of RSPM Parameter Units A-1 A-2 A-3 A-4 A-5 A-6 A-7 Sio2 µg/m3 6.02 6.15 6.56 6.45 6.52 6.50 6.61 Ca µg/m3 3.04 3.21 3.75 3.88 2.71 3.39 3.88 Fe µg/m3 2.95 2.94 3.01 2.96 3.64 2.94 2.96 Cr µg/m3 0.01 0.01 0.01 BDL 0.01 0.01 BDL Zn ng/m3 0.18 0.29 0.11 0.17 0.11 0.26 0.17 PAH ng/m3 BDL BDL BDL BDL BDL BDL BDL

A1- Site, A2- Bontapalli, A3- Gummadidala, A4- Annaram, A5- Jinnaram, A6- Kanukunta & A7- Srirangaram



3.5 Noise Environment

Noise is an unwanted sound without musical quality. Artificial noise and its impact

on environment, grown apace with advancing human civilization. Noise pollution

is equally hazardous to environment as air, water and other forms of pollution.

Various noise measurement units have been introduced to describe, in a single

number, the response of an average human to a complex sound made up of various

frequencies at different loudness levels. The most common scale is, weighted

decibel dB (A), and measured as the relative intensity level of one sound with

respect to another sound (reference sound).

The impact of noise depends on its characteristics (instantaneous, intermittent or

continuous in nature), time of day (day or night) and location of noise source. Table

3.11 shows the effects of different noise levels on human beings. The environmental

impact of noise can have several effects varying from noise induced hearing loss to

annoying depending on noise levels.

The assessment of noise pollution on neighborhood environment due to the industry

was carried out keeping in view, all the considerations mentioned above. The

existing status of noise levels is measured at 8 locations at various villages within the

study area. Figure 3.10 shows noise level measured locations. The measured noise

values are shown in Table 3.12. Noise levels are high at the traffic junctions

compared to the industrial and village areas. The highest noise levels are observed

at site i.e., 55 dB (A) during day time and extremely low at Bontapalli i.e., 36 dB (A)

during night time in the study area at the time of measurement.



Figu

re 3

.10

Noi

se S

ampl

ing

Loca

tions



Table 3.11 Effects on Human Beings at Different Noise Levels Source Noise Level dB(A) Effects

Large Rocket Engine (near by) 180 Threshold of Pains Hydraulic Press ( 1 m ) 130 Jet take off (60 m) 120 Maximum vocal effort

possible Automobile Horn (1m) 120 Construction Noise (3m) 110 Jet Take off (600 m) 110 Shout, Punch, Press, Circular Saw 100 Very annoying Heavy Truck (15m), Farm Machinery 90 Prolonged exposure

Endangers Lathes, Sports Car, Noisy Machines hearing loss

Automobile (15m) 80 Annoying Freeway Traffic (15m) 70 Telephone is difficult,

intrusive Loud Conversations 60 Living Room in Home 50 Quiet Power Station (15m) 50 Bed Room in Home 40 Soft Whisper (5m) 30 Very quiet Tick of Wall clock (1m) 30 Low radio Reception 20 Whisper 20 Rattling of Leaves by Breeze 10 Barely audible 0 Threshold of hearing

Table 3.12 Equivalent Noise levels in the Study Area (Terms of Reference No. 6(vii)

S.No. Location Equivalent Noise Levels dB(A) Leq day Leq night

1. Plant site 55 42 2. Bontapalli 48 36 3. Gummadidala 51 39 4. Annaram 49 38 5. Jinnaram 49 40 6. Kanukunta 46 37 7. Srirangaram 49 38



3.6 Socio Economic Environment (Terms of Reference No. 6(xi))

Industrial development reflects in social development, i.e., growth in infrastructure

facilities, growth in employment rates, increased demands for housing, and other

amenities etc., which will have a bearing on the socio economic status.

Socio-economic survey is conducted to ascertain the existing socio-economic status

to compare the same with the developments due to the project. Baseline data of

demographic characteristics- occupational status, literacy, health status and the

access to infrastructure facilities for social development in the project area has been

studied from the secondary data collected from census department By M/s. Team

Labs and Consultants.

Demographic characteristics of the study area falling within 10 km radius of the

project site have been compiled to assess the pre-project socio-economic status.

Secondary data has been collected from various government agencies i.e., chief

planning officer, Medak& Rangareddy district and other government departments

of forestry, irrigation etc., and Mandal Development Offices of the relevant

government departments.

3.6.1 Demography

The study area falls under the following mandals of Medak& Rangareddy district;

Jinnaram, Shivampet, Narsapur, Hathnoora and district, Qutubullapur & Medchal

respectively. Study area comprises of 41 revenue villages and 12 hamlets.

3.6.1.1 Population Distribution

The population distribution of the study area is presented in Table 3.13. The total

population of the area is 101506 consisting of 53244 males and 48262 females. The

population density is observed to be low reflecting on the terrain, low quality of soils

and absence of reliable irrigation sources. The population of the scheduled castes is

13654 consists of 6826 males and 6828females, while the scheduled tribe population

is 3365 consists of 5490 males and 1685 females, which is 13.45 and 3.3 % of the total

population respectively.



Table 3.13 Population Distribution – Study Area

Category Population Total Population 101506 Male 53244 Female 48262 Population <6 years 15194 Male <6 years 7846 Females < 6years 7348 Scheduled Caste Population - Total 13654 Male – SC 6826 Female – SC 6828 Scheduled Tribe Population - Total 3365 Male – ST 1680 Female – ST 1685

3.6.1.2 Literacy

Census operations consider a literate as a person who is above six years old and who

can write and read as per the census. Table 3.14 presents the literacy levels in the

study area.

The population below six years old is 15194 consists of 7846 males and 7348 females,

which is 14.96 % of the study area population. It may be observed that the literacy

levels among females in general are low compared to the literacy levels among

males.

Table 3.14 Literacy - Study Area Category Population Total Population 101506 Total Population – Male 53244 Total Population - Female 48262 Population <6 years 15194 Male <6 years 7846 Females < 6years 7348 Total Literates 51834 Male –Literates 32623 Female – Literates 19211 Total Illiterates 49672 Male –Illiterate 20621 Female – Illiterate 29051

The percentage of literacy level in the study area among males is 32.13 and 18.93

among females. It may be observed that the literacy level among females is

comparatively less than males.



3.6.1.3 Employment/Occupation

Work is defined as participation in any economically productive activity -

Physical/mental. The work force is classified into three categories: a) main workers,

b) marginal workers and c) non-workers. Main workers are those who work for a

substantial part of the year for a living such as salaried employees, agricultural labor

etc. Marginal workers are those who worked the previous year but have not

worked for a substantial part of this year. Non-workers constitute students, house

wives, dependents, pensioners etc. Table 3.15 presents the population distribution

for employment.

It may be observed that a majority of the study area population falls in the non

worker category, and the marginal workers form about 9.13% of the total

population. The male female difference is also significant in all the regions and in

all the categories. There are few females among the workers where as there are

more non workers and marginal workers among females.

Table 3.15 Employments - Study Area Category Population Total Population 101506 Total Population – Male 53244 Total Population – Female 48262 Total Main Workers 39774 Main workers – Male 28630 Main Workers – Female 11144 Total Marginal Workers 9301 Marginal Workers – Male 3633 Marginal Workers – Female 5668 Total Non Workers 52431 Non Workers – Male 20981 Non Workers – Female 31450

The main workers are further classified into; Total cultivators: those who engage a

single worker or his family member to cultivate land for payment in money, kind or

share; Agricultural labor: those who work in other’s lands for wages; Livestock,

forestry, fishing and allied activities; Workers involved in mining and quarrying;

Workers involved in manufacturing and processing industries in the house hold

industries; non house hold industries; construction workers; workers in trade and

commerce; workers involved in transport, storage and communication ; and other



services: government employees, teachers, priests, artists etc. Table 3.16 presents

the main workers distribution among the study area population.

It may be observed that over 8.3 % of the study area population is involved in

cultivation or agriculture labor, followed by other services to the tune of 8.4%. It may

also be observed that the people involved in non household industry are

significantly more reflecting on the industrial nature of the area. Significant

differences are observed among the male and female workers, Female workers are

found to be more in agricultural activity largely due to more percentage of females

being agricultural labor.

Table 3.16 Main Workers - Study Area Category Population Total Population 101506 Total Population – Male 53244 Total Population – Female 48262 Total Main Workers 39774 Main workers – Male 28630 Main Workers – Female 11144 Total Cultivators 8393 Cultivators – Male 5821 Cultivators- Female 2572 Total Agriculture Labor 8534 Agriculture Labor – Male 4102 Agriculture Labor – Female 4432 Total Household Workers 693 Household Workers – Male 438 Household Workers – Female 255 Total Others 22154 Others – Male 18269 Others – Female 3885

3.6.2 Living Standards and Infrastructure

Sustainable development of any area is dependent not only the population but also

on the availability of infrastructure which leads to better living standards. The

infrastructure facilities are essential in providing education, awareness, health,

communication, potable water, transport etc. The standards of living are the sum of

the availability of the infrastructure to the subject community, wide variations in

terms of income, economic conditions and patterns of spending.



The infrastructure facilities available in the impact zone are reflecting the rural

nature of the entire study area.

I. Educational Facilities

The educational facilities available in the rural areas are meager. There are 72

primary schools, 35 middle schools and 3 high schools in the study area. There are

two junior colleges in the area. Four of the villages in the study area do not have any

educational facilities. The higher educational need of the population is met by

Jinnaram and Medchal.

II. Health facilities

The medical and health facilities available in the impact zone are inadequate; there

are 3 PHC, 15 PHS and 1 child welfare center and 1 RP centre in the entire area. The

health needs of the population in this area are met by quacks and other semi

qualified persons.

III. Availability of Potable Water

The entire population in this area is dependent on ground water for drinking

purposes. About 14 villages in the study area are dependent on tube wells, while

the remaining villages are dependent on wells and hand pumps.

IV. Transport and Communication

Transport is essentially provided by the Telangana State Road Transport

Corporation (TSRTC). Most of the study area has excellent road network in all the

villages except in one village, which has kacha roads. TSRTC bus facility is

available for the all the villages. However it is observed that a number of private

transport vehicles are observed in the area connecting them to Jinnaram and

Medchal.

V. Sources of Energy and Availability

The primary source of energy in the study area is electricity, and the entire study

area has electricity for agriculture and domestic purpose. The urban areas have

LPG facility for their cooking purpose. A significant number of people in the urban

area are also dependent on Kerosene for cooking purposes, which is contingent on

the vagaries of public distribution system. A majority of the rural area is mostly



dependent on Kerosene, dried cow dung cakes, wood from roadside trees for their

domestic energy needs.

VI. Post and Telegraph facilities

There are 21 post offices in the area and one post & Telegraph office in the study

area. Phone facilities however are extended to some of the villages.

VII. Housing

Census defines the house hold as a group of persons living together and sharing

their meals from a common kitchen. The number of households in the impact zone

is 22509, while the number of the houses is 21408. The density of the households is

approximately five. The traditional houses made up of mud walls and covered by

dry common grass and leaves of bourses are commonly found in the rural area,

which are not considered pucca houses. The government has been augmenting the

housing standards by constructing housing colonies for various weaker sections of

the society.

3.6.3 Land Utilization

Land use patterns can be prepared on the basis of revenue records though it is not an

exact indicator of the actual use of the land at a given time. The impact zone has a

large area in the coast and the ocean, where land is essentially marshy on the coast.

Land use is presented under the heads of area under forest cover irrigated land, area

under cultivation and cultivable wasteland in Table 3.17.

Table 3.17 Land Utilization Pattern Category Area in Ha Forest Land 4088 Irrigated Land 4188 Culturable waste Land 4554 Unculturable Waste Land 8162 Unirrigated Land 8272 Total Land 292614

It may be observed that a majority of the study area is unirrigated, followed by

Unculturable Waste Land and Culturable waste Land.



3.6.4 Project Economy

M/s. Virchow Drugs Limited Expansion of Bulk Drugs Unit in an area of 3 acres at

Sy. No. 639 (Part), Bonthapally IDA, Jinnaram Mandal, Medak District, Telangana.

It will be spending approximately 600 Lakhs of rupees every month on salaries

providing bread and succor to 800 families additionally. The proposed project will

also generate indirect employment to the locals during construction phase. The

employers will contribute to the provident fund, ESI and provide facilities as per the

relevant labor act.

The proximity of Jadharla town will provide access to the extensive medical facilities

available apart from the ESI medical facilities to the employees and their families. An

industrial Canteen is established by the company.

It may be concluded that satisfactory amenities are available for the population of

the impact zone, while the amenities are available either within the village or at a

minimum distance of 6 km. The area also has large tracts of waste lands which can

be utilized for industrial development.

3.7 Flora and Fauna (Terms of Reference No. 6(x))

3.7.1 Flora of the core area

Except for a few weeds, most of the natural vegetation and flora of the industrial site

was lost and it is replaced by avenue plantations, block plantations, lawns and

gardens. A list of plants present in the core area is given in Table 3.18. In addition to

the list of species grown in the premises of the industry, Siam Weed (Chromolaena

odorata) and Hyptis suaveolens were seen quite often in the campus.

Table 3.18 List of trees and shrubs found in the premises of the bulk drug unit

Acacia auriculiformis Australian wattle Ailanthus excelsa Avenue tree Albizia lebbeck Siris Alstonia scholaris Tree Araucaria columnaris Araucaria Azadirachta indica Neem Callistemon lanceolatus Bottle brush tree Cassia fistula Amaltas Crataeva religiosa Sacred plant Cupressus sempervirens Cupressus



Dalbergia sissoo Sissoo Delonix regia Tree Dendrocalamus strictus Bamboo Eucalyptus tereticrnis Nilgiri Ficus benjamina Tree Grevillea robusta Silver Oak Holoptelia integrifolia Tree Leucaena leucocephala Subabul Millingtonia hortensis Tree Mimusops elengi Tree Peltophorum pterocarpum Copper pod Plumeria rubra Tree Polyalthia longifolia Tree Polyalthia pendula Tree with drooping branches Pongamia pinnata Biodiesel plant Spathodea companulata Trumpet Flower tree Swietenia mahogoni Mahogany Syzygium cumini Jamun Tamarindus indica Tamarind Ttectona grandis Teak Terminalia arjuna Arjuna Terminalia catappa Badam Thuja occidentalis Thuja Ornamental shrubs Acalypha hispida Red-hot cattail Bougainvillea spp., Ornamental varieties Barleria cristata Philippine violet Cestrum diurnum Din Ka Raja Cycas revoluta Sago cycas Duranta repens Suitable as a hedge plant Ervatamia divaricata = Tabernaemontana divaricata

Tabernaemontana

Ervatamia coronaria Grape jasmine Hamelia patens Fire bush or Scarlet bush Hibiscus rosasinenisis China rose Ixora parviflora Ixora Lagerstroemia speciosa Giant Crape-myrtle Lantana camara Ornamental Lantanas Mussaenda erythrophylla Red Mussaenda Mussaenda luteola Dwarf Yellow Mussaenda Nyctanthes arbortristis Night-flowering Jasmine Nerium indicum Nerium Poinsettia pulcherrima Poinsettia Plumbago capensis Cape Plumbago Pentas carnea Pentas Rosa spp. (Roses) Roses Russelia juncea Firecracker Plant Russelia floribunda Russelia Tecoma capensis Cape Honeysuckle Tecoma stans Yellow bell



Thuja compacta Thuja Thevetia peruviana Yellow Oleander

3.7.2 Vegetation and Flora of the Buffer zone

There are no ecologically sensitive areas such as biosphere reserves, national parks,

wildlife sanctuaries, important birdlife areas (IBA), wetlands or migratory corridors

of wildlife within the 10 Km buffer zone. But there are patches of Deccan dry

deciduous forests mainly towards the West and Northwest of the bulk drug unit. A

list of trees, shrubs and perennial climbers found in the buffer zone is given in Table

3.19. Besides the species given in the Table, all common cultivated fruit trees such as

Mango, Sapota, Guava, Jamun and others are also found in the buffer zone. A list of

grasses found in the buffer zone is given in Table 3.20.

Table 3.19 List of trees, shrubs and perennial climbers found in the buffer zone of the industry

Scientific name Common or Local name Family Acacia ferruginea Pandra Khair Mimosaceae Acacia auriculiformis Australian Wattle Mimosaceae Acacia caesia Korintha Mimosaceae Acacia catechu Khair / Nalla sandra Mimosaceae Acacia farnesiana Muriki thumma Mimosaceae Acacia leucophloea Tella tumma Mimosaceae Acacia nilotica Nalla tumma Mimosaceae Acacia planifrons Godugu Thumma Mimosaceae Acacia sundra Sundra Mimosaceae Acaia holosericea Holosericea Mimosaceae Acaia horrida Parikithumma Mimosaceae Acaia instia Korinta Mimosaceae Achrus sapota Sapota Sapotaceae Aegle marmelos Maredu Rutaceae Ailanthus excelsa Peddamaanu Simaroubaceae Alangium salvifolium Ooduga Alangiaceae Albizia lebbek Dirisanam Mimosaceae Alhagi camelorum Camel thorn Fabaceae Allamanda cathartica Allamanda Apocynaceae Anacardium occidentale Cashew nut Anacardiaceae Annona squamosa Custard apple Annonaceae Anogeissus acuminata Pasi Combretaceae Anogeissus latifolia Chirumaanu Combretaceae Asperagus racemosa Satavari Liliaceae Azadirachta indica Vepa Meliaceae Azima tetracantha Tella Uppili Salvadoraceae Bassia latifolia Ippa Sapotaceae Bauhinia racemosa Aare chettu Caesalpiniaceae Bauhinia variegata Mandari Caesalpiniaceae



Scientific name Common or Local name Family Benkara malabarica Pedda manga Rubiaceae Bombax ceiba Booruga Bombacaceae Bombax malabariucm Silk cotton Bombacaceae Borassus flabellifer Taati / Taadi Araceae Breynia retusa Chinna purugudu Euphorbiaceae Breynia vitis-ideae Nalla purugudu Euphorbiaceae Buchanania angustifolia Pedda -mori Anacardiaceae Buchanania latifolia Char / Sarapappu Anacardiaceae Butea monosperma Modugu Fabaceae Callistemon citrinus Indian bottle brush tree Myrtaceae Calotropis gigantea Tella Jilledu Asclepiadaceae Calotropis procera Jilledu Asclepiadaceae Calycoperis floribunda Bonta teega Combretaceae Canthium dicoccum Nalla balusu Rubiaceae Canthium parviflorum Balusu Rubiaceae Capparis zeylanica Kutajamu Capparidaceae Careya arborea Vaikumbha Myrtaceae Carissa spinarum Kalivi / Vaaka Apocynaceae Cascabela thevetia Patcha ganneru Apocynaceae Cassia auriculata Tangedu Caesalpiniaceae Cassia fistula Rela Caesalpiniaceae Catunaregam spinosa Manga / Chinna manga Rubiaceae Celastrus paniculata Dante Celastraceae Chloroxylon sweitenia Billudu Flindarsiaceae Cissus vitiginea Adavi Gummadi Vitaceae Cocos nucifera Coconut Araceae Codioeum varieigatum Croton Euphorbiaceae Cordia dichotoma Bankiriki Cordiaceae Cosmostigma racemosum Adavitamalapaaku Apocynaceae Crataeva religiosa Urimidi Capparidaceae Cryptostegia grandiflora Rubber vine Asclepiadaceae Daemia extensa Asclepiadaceae Dalbergia sisso Sisso or Seesum Caesalpiniaceae Decalepis hahiltonii Maredu kommulu Periplocaceae Dendrocalamus strictus Bamboo / Veduru Poaceae Desmodium pulchellum Deyyapu mokka Fabaceae Dichrostachys cinerea Sara Thumma Mimosaceae Diospyros chloroxylon Ulinda Ebenaceae Diospyros melanoxylon Tunki Fabaceae Dodonaea viscosa Bandedu Sapindaceae Dolichondrone crispa Nirwodi Bignoniaceae Dolichondrone falcata Wodi Bignoniaceae Erythina indica Indian coral tree Papilionaceae Erythroxylon monogynum Dedaraaku Erythroxylaceae Eucalyptus teretocronis Eucalyptus Myrtaceae Eucalyptus hybrid Eucalyptus / Nilagiri Myrtaceae Euphorbia caducifolia Brahma jemudu Euphorbiaceae Ficus benghalensis Marri Moraceae Ficus racemosa Medi Moraceae



Scientific name Common or Local name Family Ficus religiosa Raavi Moraceae Givotia rottleriformis Tella Poliki Euphorbiaceae Glycomis mauritiana Tanaka Rutaceae Grevellia robusta Silver oak Proteaceae Grewia flavescens Jaana Tiliaceae Grewia hirsuta Jaani Chettu Tiliaceae Grewia obtusa Jaana Tiliaceae Grewia orbiculata Pedda Jaani Tiliaceae Grewia tillifolia Pedda Jaana Tiliaceae Grewia villosa Bantha Tiliaceae Hardwickia binata Yepi Caesalpiniaceae Hemidemus indicus Sugandhapala Periplocaceae Heterophragma roxburghii Bondudgu Bignoniaceae Holoptelia integrifolia Nemali naara Ulmaceae Ipomoea carnea Rubber mokka Convolvulaceae Jatropha glandulifera Wild Castor Euphorbiaceae Kigelia africana Yenugu Paadam Bignoniaceae Lagerstroemia parviflora Chennangi Lythraceae Lantana camara Lantana Verbenaceae Leptadenia reticulata Mukkupala Teega Asclepiadaceae Leucaena leucocephala Subabul Mimosaceae Limonia acidissima Velaga Rutaceae Mangifera indica Mamidi Anacardiaceae Maytenus emerginata Danti Celastraceae Millingtonia hortensis Aakaasa malle Bignoniaceae Mimosa polyancistra Thumma Mimosaceae Mimosa rubicaulis Pariki kampa Mimosaceae Mimosops elengi Pogada Sapotaceae Morinda pubescens Togaru Rubiaceae Moringa olivaefera Munaga Moringaceae Muntingia calabura Wild cherry Elaeocarpaceae Odina wodier Gumpena Anacardiaceae Oroxylum indicum Dundilam Bignoniaceae Parkinsonia aculeata Jeeluga Widespread Peltophorum pterocarpum Konda chinta Caesalpiniaceae Pergularia daemia Dustapa teega Asclepiadaceae Phoenix sylvestris Eetha Araceae Phyllanthus emblica Usiri Euphorbiaceae Phyllanthus reticulatus Pulasari / Puliseru Euphorbiaceae Pithecellobium dulce Seema chinta Mimosaceae Plumeria acutifolia Temple tree Apocynaceae Plumeria alba Tella devaganneru Apocynaceae Plumeria rubra Erra devaganneru Apocynaceae Polyalthia cerasoides Tella chilkadudi Annonaceae Polyalthia longifolia Ashoka Annonaceae Polyalthia pendula Asoka Annonaceae Pongamia pinnata Ganuga Fabaceae Prosopis juliflora English tumma Mimosaceae Prosopis spicigera Jammi chettu Mimosaceae



Scientific name Common or Local name Family Quisqualis indica Rangoon creeper Combretaceae Rauwolfia tetraphylla Bara Chandrika Apocynaceae Ricinus communis Castor Euphorbiaceae Saccopetalum tomentosum Chilka dudi Annonaceae Samanea saman Nidrabhangi Mimosaceae Sapindus emarginatus Kunkundu Sapindaceae Sarcostemma bevistigma Som Asclepiadaceae Semecarpus ancardium Marking nut tree Anacardiaceae Spathodea companulata Flame of the forest Bignoniaceae Spondias mangifera Konda maamidi Anacardiaceae Sterculia foetida Adavi badam Sterculiaceae Strychnos nux-vomica Usti Loganiaceae Syzigium cumini Neradu Myrtaceae Tabermantana coronaria Nandivardhanam Apocynaceae Tamarindus indica Chinta Caesalpiniaceae Tecoma stanns Patcha turai Bignoniaceae Tectona grandis Teak / Teku Verbenaceae Terenna asiatica Kommi Rubiaceae Terminalia arjuna Tella maddi Combretaceae Terminalia bellerica Taani / Taandra Combretaceae Terminalia catappa Baadam Combretaceae Terminalia tomentosa Nalla maddi Combretaceae Thespecia populnea Ganga Raavi Malvaceae Thevetia nerifolia Yellow oleander Apocynaceae Tylophora indica Kukkapala teega Asclepiadaceae Vitex negundo Vaavili / Nirgundi Verbenaceae Wattakaka volubilis Tummudu teega Asclepiadaceae Wrightia tinctoria Pala –kordusha Apocynaceae Ziziphus numularia Nela regu Rhamnaceae Ziziphus rugosus Regu Rhamnaceae Ziziphus xylopyra Goti or gotti Rhamnaceae

Table 3.20 List of grasses and sedges found in the buffer zone during the summer

season Scientific name Family Importance Alloteropsis cimicina Poaceae Fodder Andropogon jwarancusa Poaceae Fodder grass Aristida depressa Poaceae Fodder Aristida hystrix Poaceae Fodder in early stages Aristida setacea Poaceae Used for making brooms Bothriochloa pertusa Poaceae Fodder grass Brachiaria cruciformis Poaceae Fodder grass Brachiaria distachya Poaceae Fodder grass Brachiaria mutica Poaceae Fodder grass Brachiaria reptens Poaceae Fodder grass Bulbostylis barbata Cyperaceae Fodder Cenchrus ciliaris Poaceae Fodder grass Chloris barbata Poaceae Fodder grass Chrysopogon fulvus Poaceae Fodder grass



Scientific name Family Importance Cymbopogon coloratus Poaceae Aromatic non palatable perennial grass Cymbopogon caesius Poaceae Aromatic non palatable perennial grass Cynodon dactylon Poaceae Palatable fodder and soil binder Cyperus rotundus Cyperaceae Nut grass, a notorious weed Dichanthium annulatum Poaceae Palatable fodder gass Dichanthium caricosum Poaceae Palatable fodder gass Eremopogon faveolatus Poaceae Palatable fodder grass Heteropogon contortus Poaceae Fodder when young

3.7.3 Terrestrial Fauna of the study area

As the core are is under intensive industrial use and surrounded by a compound

wall on all sides, there are no chances of occurrence of any wild animals other than

the rodents that are found in any residential area. Rats, bandicoots, mice, squirrels

and lizards are some of the natural fauna that is found in the core area as well as in

nay other locality. A list of terrestrial vertebrates other than birds either spotted or

reported from the study area is given in Table 3.21. Among the snakes, Cobras,

Kraits, Vipers have been reported along with the common non-poisonous snakes.

Monitor lizards are also common. A list of birds found or reported from the study

area is given in Table 3.22. Pea Cocks and Pea Fowls are quite common. They were

found in groups of 2 to 8. Though they (Pea Cocks and Pea Fowls) are our national

bird and included in Schedule of the Indian Wildlife (protection) Act, they are placed

in the LC (least concern) category by the IUCN. If permitted, it is easy to domesticate

and multiply them.

3.7.4 Rare and Endangered animal reported in May 2013

It was reported that a Leopard was seen by locals in Bonthaplly Reserve Forest

located at a distance of about 3.4 Km towards West of the industrial site on 21-4-

2013 but attempts by the forest department and the survey team failed to find any

evidence of its occurrence. Hence it is highly doubtful but it can not be totally

dismissed as stray incidents of entry of leopards in to human jungles have been

reported now and then.



Table 3.21 List of vertebrates other than birds found in and around the project site

Common name Scientific name Local name MAMMALS Large bandicoot rat Bandicota indica Pandikokku Short-nosed fruit bat Cynopterus sphinx Gabbilam Three striped squirrel Funambulus palmarum Udatha Indian bush rat Golunda ellioti myothrix Yeluka Indian grey mongoose Herpestes edwardsinyula Mungeesa Indian crested porcupine Hystrix indica Mullapandi Common Indian field mouse Mus booduga Yeluka Mouse Mus musculus homeurus Yeluka Home mouse Mus musculus tytleri Yeluka Bandicoot rat Nosokia indica indica Pandikokku Leopard Panthera pardus * (NT) Chirutha Puli Indian pygmy pipistrelle Pipistrellus mimus mimus Gabbilam Long-eared bat Plecotus auritus homochrous Gabbilam Common Indian rat Rattus rattus gangutrianus Yeluka Common Indian rat Rattus rattus refescens Yeluka Greater yellow bat Scotophillus heathi heathi Gabbilam Savvy pygmy shrew Suncus etruscus micronyx Chuchu House shrew Suncus murinus tytleri Chuchu Wild boar Sus scrofa Adavi Pandi REPTILES Chameleon Chameleon zeylanicus Oosaravelli Cobra Naja naja Naagu paamu Common Indian Krait Bungarus caeruleus Katla paamu Common Indian Monitor Varanus bengalensis Udumu Garden lizard Calotes versicolor Thonda Giant Blind Snake Typhlops diardii Rendu talala

paamu Indian python Python molurus Kond chiluva Indian star tortoise Geochelone elegans Nakshatra

taabelu Rat snake Ptyas mucosa / Tripidonatus pisactor Jerri pothu Russell’s viper Vipera russseli Rakta pinjari Saw scaled viper Echis carinatus Pinjari Slender Blind Snake Typhlops porrectus --- Indian wall lizard Hemidactylus flaviviridis Balli Tree Snake Chrysopelea taprobanica Pasirika paamu Whip Snake Dryphis nasutus --- AMPHIBIANS Indian Burrowing frog Sphaerotheca breviceps Burada kappa Green Pond Frog Rana hexadactyla. Kappa Common Indian Toad Bufo melonosticatus Toad Tiger Frog Hoplobatrachus tigerinus (Rana

tigerina) Kappa

Tree Frog Hyla arboria Chettu kappa



Table 3.22 List of Birds either spotted or reported from the areas in and around the project site.

Scientific Name Common Name Family WPA Schedule

Accipiter badius Shikra Accipitridae IV Acridotheres tristis Common myna Sturnidae IV Aegithinia tiphia Common Iora Irenidae IV Alcedo atthis Smallblue kingfisher Alcedinidae IV Amaurornis phoenicurus White-breasted waterhen Recurvirostridae IV Anas poecilorhyncha Spot-billed duck Anatidae IV Ardea cinerea Grey Heron Ardeidae IV Ardeola grayii Pond Heron Ardeidae IV Athene brama Spotted owlet Noctuidae IV Bubulcus ibis Cattle Egret Ardeidae IV Centropus sinasis Greater coucal Phasianidae IV Ceryle rudis Lesser pied Kingfisher Alcedinidae IV Columba livia Blue rock pigeon Columbidae IV Coracias benghalensis Indian roller Coraciidae IV Corvus splendens House crow Corvidae V Dendrocitta vagabunda Indian tree pie Corvidae IV Dendrocygna javanica Lesser whistling-duck Anatidae IV Dicaeum erythrorhynchos Tickell’s flower pecker Dicaeidae IV Dicrurus macrocercus Black drongo Dicruridae IV Egretta garzetta Little egret Ardeidae IV Elanus caeruleus Black-shouldered kite Accipitridae IV Eudynamys scolopace Asian koel Cuculidae IV Fulica atra Coot Rallidae IV Gallinula chloropus Indian Moorhen Rallidae IV Halcyon smyrnensis White-Breasted King

fisher Alcedinidae IV

Hierococcyx varius Brain fever bird Ardeidae IV Himantopus himantopus Black-winged stilt Recurvirostridae IV Hydrophasianus chrugus Pheasant tailed Jacana Jacanidae IV Lanius excubitor Great grey shrike Daniidae IV lxobrychus cinnamomeus Chestnut bittern Ardeidae IV Megalaima haemacephala Copper smith Barbet Capitonidae IV Merops orientalis Small Bee eater Meropidae IV Milvus migrans Black kite Accipitridae IV Motacilla alba White wagtail Motacillidae IV Motacilla flava Yellow wagtail Motacillidae IV Motacilla maderaspatensis Large pied wagtail Motacillidae IV Nectarinia asiatica Purple sunbird Nectariniidae IV Nectarinia zeylonica Purple-rumped sunbird Nectariniidae IV Oriolus oriolus Eurasian golden oriole Oriolidae IV Passer domesticus House sparrow Passeridae IV Pavo cristatus Pea cock / Pea Fowl

(National Bird) Phasianidae I (LC as

per IUCN)

Perirocotus cinnomomeus Small Minivet Phasianidae IV Phalacrocorax carbo Large Cormorant Phalacrocoracidae IV



Scientific Name Common Name Family WPA Schedule

Phalacrocorax niger Little cormorant Phalacrocoracidae IV Porphyrio porphyrio Purple moorhen Rallidae IV Prinia inornata Plain prinia Cisticolidae IV Prinia socialis Ashy prinia Cisticolidae IV Psittacula cyanocephala Blossom headed

Parakeet Psittacidae IV

Psittacula krameri Rose-Ringed Parakeet Psittacidae IV Pycnonotus cafer Red-vented bulbul Pycnonotidae IV Saxicolodies fulicata Indian robin Turdinae IV Streptopelia chinensis Spotted dove Columbidae IV Streptopelia decaocto Eurasian Collared-Dove Columbidae IV Streptopelia Senegalensis Little brown dove Columbidae IV Streptopelia tranquebarica Red Collared-Dove Columbidae IV Sturnus pagodarum Brahminy starling Sturnidae IV Terpsiphone paradisi Asian paradise-

flycatcher Muscicapidae IV

Turdoides caudatus Common babbler Timalinae IV Upupa epops Common hoopoe Upupidae IV Vanellus indicus Red-wattled lapwing Charadriidae IV



CHAPTER 4.0 IDENTIFICATION OF IMPACTS

4.1 Identification of Impacts

Identification of Impacts is one of the basic analytical steps of EIA for subsequent

prediction and evaluation of impacts. A number of methodologies are available for the

identification of impacts. `Net Work Method,' which follows the “Cause-Condition-

Effect” relation ship, is adopted for identifying impacts due to the M/s. Virchow Drugs

Limited, M/s. Granules India Limited (formerly known as Auctus Pharma Unit III), Sri

Gayatri Drugs Pvt. Ltd., Hetero Drugs Limited, Unit – I, M/S. Hetero Drugs Limited,

Unit – I and Honour Labs IDA Bonthpally, Medak District.

The generation of cause - condition - effect networks (chain of events) should follow the

above mentioned activities and actions. This type of method is advantageous in

recognizing the series of impacts triggered by the plant activities. Thus this method has

provided a “road mass” type of approach to the identification of second and third order

effects.

The idea was to account for the project activity and identify the different types of

impacts that would initially occur. The next was to select each impact and identify the

impacts. The main advantage of this approach is that it allowed identifying the

impacts by selecting and tracing out the events as they may occur.

4.2 Impact Networks

The purpose of identifying the impacts is that it aids in making appropriate decision to

mitigate the adverse consequences if any. It may be pointed out that the distinction

between magnitude and importance of impact should be appreciated. Thus the degree

of extensiveness and scale of impacts and the consequences based on value judgments

are generalized while identifying impacts; as it is imperative that the impact will

normally lead to a chain of reactions. The construction of network charts brings out to

certain extent the appropriate levels of risks that may occur due to the interventions

while interacting with hydrological, biological and social systems. Figure 4.1 to 4.6

present the identified impacts for various components of environment viz. air, noise,

water, land and socio economic aspects. In the above-mentioned Figure the lines mean -

- "has an effect on."



4.2.1 Air Environment

The primary impact of air pollutants will be on the air quality. The chemical

composition of air may change drastically if dispersion is slow. This will lead to, if

pollution is for a shorter period, immediate health problems. If it continues for a long

period, it may also have an impact on climatic changes, ecological equilibrium and

economic production of crops. The impacts on air environment from the expansion of

the project shall be due to utility emissions, process emissions, diffuse and fugitive

emissions. The impacts due to the project shall be felt mainly within the plant area and

the immediate surroundings. There shall be an increase in ambient air concentrations,

unless mitigative and control measures are adopted. The mitigative and control

measures of air pollution shall ensure that the impact on air quality is local – within the

site area and its surroundings, with low magnitude, medium term duration, and an

irreversible impact.

4.2.2 Water Environment

Wastewater will affect the environment both directly and indirectly primarily it may

affect the land and water quality. This leads to deterioration of production levels of

both terrestrial and aquatic flora and fauna, resulting in higher concentrations of

chemicals in food chain. The impacts on water environment are due to abstraction of

ground water, effluents from process, utilities an domestic sources, and spillage of

chemicals, effluents and solid wastes during storage, transfer and due to spillages of

the same. The impacts on surface water quality shall be neutral, reflecting locally

within the site, with low magnitude short term impact mainly due to spillage scouring

during monsoon season’s first rain, which is reversible in short term. The impact on

hydrology is neutral as the proposed expansion does not involve any major

construction activity. The impact on hydrogeology shall be negative as it is proposed

to utilize ground water resulting in impacts at regional level with medium magnitude

for a medium term, continuous frequency, and is reversible in the long term.

4.2.3 Noise Environment

The noises will primarily affect the ambient noise levels. Excessive noise will trigger

health risks such as headaches, depression, deafness and retardation of sensory

mechanisms in the impact area population. The impacts on noise environment are due



to mechanical activities, and operation of pumps, motors, and compressors. The

increase in noise levels shall have neutral impact, restricted to within site area due to its

low magnitude and occasional frequency.

4.2.4 Land Environment

The change in the land use during and after the construction phase is unavoidable.

However as long as it is not affecting the soil quality chemistry and sedimentation, the

impact is not an undesirable one. At the secondary level the impact will lead to

change of agricultural production and livestock. The impact on land environment is

mainly due to accidental spillages of chemicals, effluents and wastes. The project has

negative impact on land environment, terrain and soils as there is a change in land use,

and the impacts are restricted to within the site with negligible magnitude and is felt

mainly during construction work only. The operational phase impacts shall be neutral

due to effective implementation of mitigative measures in handling, storing and

transferring wastes, effluents and chemicals, and development of green belt.

4.2.5 Biological Environment

The particulate matter and chemical compounds tend to alter soil matrix and water

quality. The impact will be on the native biota leading to density reduction and

extinction of sensitive species. There may be change in the species diversity and food

chain. The expansion activity does not involve disturbance of land or habitat. The

impact on biological environment is neutral with the effect confined mainly to the site

area with low magnitude for a medium term with isolated frequency. There will be

neutral effect on wildlife as the project impact area is mainly suburban in nature and

the reserve forests of the impact area are not very dense devoid of any major wild life.

4.2.6 Socio-economic Environment

Primarily, the impact is expected on the economic environment. The generation of jobs

will occur during operation and construction phases. There is scope of multiplier effect

on secondary and tertiary employment. The socio economic structure will have a

positive change and quality of life would improve due to increase in urbanization and

cosmopolitanism. The project shall have positive impact on socioeconomic



environment due to provision of employment both direct and indirect and proposed

CSR activities.

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4.3 Prediction of Impact on Air Quality 4.3.1 Details of Mathematical Modeling A large number of different mathematical models for dispersion calculations are in

practice in many parts of the world. Most of the models for prediction of down wind

concentrations are based on Gaussian dispersion. The principle behind the Gaussian

dispersion models is Gaussian probability distribution of concentration in both vertical

and horizontal cross wind directions about the plume central line.

Predictions of ground level concentrations of the pollutants were carried out based on

site meteorological data collected during the study period. For calculation of predicted

ground level concentrations, ISCST3 model of Lakes Environmental based on USEPA,

ISCST3 algorithms, was used; as it’s based on more sophisticated algorithm

incorporating deposition, better algorithm for area sources, etc.

Brief History of the ISC Models

The ISC3 models are based on revisions to the algorithms contained in the ISC2 models.

The latter came about as a result of a major effort to restructure and reprogram the ISC

models that began in April 1989, and was completed in March 1992. The

reprogramming effort was largely motivated by the need to improve the quality,

reliability, and maintainability of the code when numerous "bugs" were discovered after

the implementation of the revised downwash algorithms for shorter stacks. However,

the goals of the reprogramming effort also included improving the user interface by

modifying the input file structure and the output products.

Overview of New Features in the ISC3 Models

The ISC3 models include several new features. A revised area source algorithm and

revised dry deposition algorithm have been incorporated in the models. The ISC3

models also include an algorithm for modeling impacts of particulate emissions from

open pit sources, such as surface coal mines. The Short Term model includes a new wet

deposition algorithm, and also incorporates the COMPLEX1 screening model algorithms

for use with complex and intermediate terrain. When both simple and complex terrain

algorithms are included in a Short Term model run, the model will select the higher

impact from the two algorithms on an hour-by-hour, source-by-source, and receptor by-



receptor basis for receptors located on intermediate terrain, i.e., terrain located between

the release height and the plume height.

Some of the model input options have changed and newer input options have been

added as a result of the new features contained in the ISC3 models. The source

deposition parameters have changed somewhat with the new dry deposition algorithm,

and there are new source parameters needed for the wet deposition algorithm in the

Short Term model. There are also new meteorology input requirements for use of the

new deposition algorithms. The option for specifying elevation units has been extended

to source elevations and terrain grid elevations, in addition to receptor elevations.

The utility programs, STOLDNEW, BINTOASC, and METLIST have not been updated.

While they may continue to be used as before, they are not applicable to the new

deposition algorithms in the ISC3 models.

The salient features of the ISCST3 model are presented below in Table 4.1. The air

quality predictions have been made using the model evaluation protocol for fugitive

dust impact modeling for surface coal mining operations (EPA 1995, EPA 1994).

Table 4.1 Salient Features of the ISCST3 Model S.No Item Details

1 Model name ISCST3 (Based on USEPA algorithm) 2 Source Types Point, Area, Volume, Open Pits 3 Dispersion Equation Steady State Gaussian Plume Equation 4 Diffusion Parameters Pasquill Gifford Co-efficient 5 Plume Rise Briggs Equation 6 Time Average 1 hr to Annual/Period Has Short Term and Long Term

modeling options 7 Deposition Both Dry and Wet Deposition 8 Application Input Data: (i) Source Data Stack co-ordinates (ii) Receptor Data Grid interval, number of receptors,receptor elevations (iii) Meteorological Data Hourly meteorological data i.e. wind speed, direction,

ambient temperature, stability and mixing heights

4.3.1.1 Model Formulation

The model uses the following steady state Gaussian plume equation. The basic

equation for calculating the concentration of pollutants for any point in x, y, z co-

ordinates is given below:



C(x,y,z,H) = Q/2π σy σz U exp[-1/2(y/σy)2] x [exp{-1/2(z-h/σz)2} + exp{-1/2 (z+H/σz)2}]

Where C= Concentration of pollutants in mg/cu m Q= Strength of emissions in g/sec. H= Effective Height (m), i.e., physical height + plume raise y, z= diffusion coefficients in y and z directions in m. U= average wind velocity in m/sec. The following assumptions are made in Gaussian dispersion model.

This model assumes no diffusion in the down wind direction and thus applicable to a

plume and not a puff of pollutant. The dispersion parameter values used for

horizontal dispersion coefficient and vertical dispersion coefficients are those given in

the “Work book of atmospheric dispersion estimates”. These dispersion coefficients

assume a sampling time of about 10 min., the height values of interest to be in the

lowest several hundred meters of the atmosphere, a surface corresponding to the open

country. The stacks are tall enough to be free from building turbulence so that no

aerodynamic down wash occurs. The given stability exists from ground level to well

above the top of the plume.

The Gaussian dispersion model has been tested extensively for its validity and found to

be reasonably applicable for different atmospheric conditions. BIS has also adopted this

basic plume dispersion model. Hence the same model is adopted for predictions of

downwind concentrations of pollutants in this report.

4.3.1.2 Meteorological Data

Data recorded by the weather monitoring station at site on wind speed, direction, solar

insolation, temperature and cloud cover at one hourly interval for three months i.e.One

full season has been used for computations. Hourly atmospheric stability determined

based on the technique suggested by Turner. Visual observations were made on for the

solar insolation and cloud cover during study period. The methodology adopted for

establishing the hourly stability class is given in Table 4.2.



Table 4.2 Atmospheric Stability Classification

Wind Speed (m/sec)

Insolation (Day time) Night time

Strong Moderate Slight Thin over cast or >4/8 low cloud <3/8 Cloud

<2 A A-B B - - 2-3 A-B B C E F 3-5 B B-C C D E 5-6 C C-D D D D >6 C D D D D

Mixing Height

The mixing heights for ambient air quality predictions are adopted from Atlas of

Hourly Mixing Height and Assimilative Capacity of Atmosphere in India by S.D Attri,

Siddartha Singh, B. Mukhopadhya and A.K Bhatnagar, Published by Indian

Metrological Department, New Delhi. 2008. The mixing heights range from 2250 to

7650 m during summer season. There is no record of inversion for this area (Reference :

Atlas of Hourly Mixing Height and Assimilative Capacity of Atmosphere in India by

S.D Attri, Siddartha Singh, B. Mukhopadhya and A.K Bhatnagar, Published By Indian

Metrological Department, New Delhi. 2008).

As the site specific mixing height is not available USEPA approved general mixing

heights as applicable for Industrial Source Complex (ISC) model have been considered

for modeling to establish the worst case scenario. The mixing heights considered for

modeling is given Table 4.3.

Table 4.3 Mixing Heights Considered for Computations Stability Class Mixing Height (m) A 1300 B & C 900 D 750 E & F 400

4.3.2 Plant Emissions

The sources of air pollution from M/s. Virchow Drugs Limited, M/s. Granules India

Limited (formerly known as Auctus Pharma Unit III), Sri Gayatri Drugs Pvt. Ltd.,

Hetero Drugs Limited, Unit – I, M/S. Hetero Drugs Limited, Unit – I and Honour Labs

IDA Bonthpally, Medak District are boilers and diesel generators. The major pollutants

generated from the fuel combustion are SO2, NOx and Particulate Matter. Based on fuel

analysis and combustion details the emission rates of above pollutants are calculated.



The emission rates of SO2, NOx and Particulate Matter from each stack are presented in

Table 4.4.

Table 4.4 Emission Details of Pollutants from Stack S.

No Stack Attached to

Stack Height

(m)

Dia of stack

at top (m)

Temp. of exhaust

gases (0C)



PM SO2 NOx Virchow Drugs Limited

Existing 1* 1TPH Oil fired

boiler 30 0.4 130 8 0.03 0.12 0.02

2# 3 TPH Coal Fired Boiler

30 0.6 160 12 0.15 0.4 0.21

3** 200KVA DG Set 3 0.1 200 10 0.003 0.08 0.01 4** 500 KVA DG set 7.5 0.2 160 15 0.004 0.16 0.03


Boiler 30 0.8 160 8.5 0.2 0.4 0.5

Granules India Limited Existing

1 1TPH Coal fired boiler

30 0.4 130 8 0.03 0.12 0.02

2** 385 KVA DG Set 3.5 0.1 185 10 0.004 0.07 0.01 Proposed

1 3 TPH Coal Fired Boiler

30 0.6 160 7.5 0.15 0.4 0.21

Sri Gayatri Drugs Existing

1 400 Kg/hr Coal fired Boiler

15 0.5 200 8 0.09 0.12 0.15

2** 92KVA DG Set 2 0.1 180 10 0.02 0.035 0.08 Proposed

1 3 TPH Coal Fired Boiler

30 0.6 160 7.5 0.15 0.4 0.21

2** 500KVA DG set 10 0.15 180 14 0.05 0.18 0.3 Hetero Drugs Limited, Unit - I

Existing 1* 8TPH CFB 30 1.3 121 6.05 0.6 0.7 0.25 2** 2 x 320KVA DG

Sets 4 0.1 145 6.5 0.002 0.07 0.1

Proposed 1 20 TPH Boiler 40 1.3 121 6.05 0.63 0.72 0.28

2** 2 x 720KVA DG Sets

6 0.2 165 8 0.07 0.18 0.3

2 x 1020KVA DG Sets

7 0.2 170 15 0.09 0.25 0.4

Hetero Drugs Limited, Unit - IV Existing

1* 10TPH Coal Fired Boiler

30 1.3 121 6.05 0.63 0.72 0.3

2** 320KVA DG Set 4 0.1 145 6.5 0.002 0.07 0.1 500KVA DG Set 5 0.15 165 7.5 0.06 0.18 0.3

Proposed



1 20 TPH Boiler 40 1.3 121 6.05 0.63 0.72 0.28 2** 2 x 1165KVA

DG Sets 7 0.2 170 15 0.95 0.28 0.4

500KVA DG Set 5 0.15 165 7.5 0.06 0.18 0.3 Honour Lab Limited

Existing 1* 0.6TPH Oil

Fired Boiler 20 0.3 160 7 0.003 0.019 0.2

2* 1.2 TPH Coal Fired Boiler

20 0.25 130 5.15 0.1 0.11 0.1

3** 110KVA DG Set 2 0.1 145 6.5 0.001 0.096 0.2 Proposed

1* 8TPH Boiler 30 1.3 121 6.05 0.6 0.7 0.25 2 20 TPH Boiler 40 1.3 121 6.05 0.63 0.72 0.28

3** 320 KVADG Set 4 0.1 145 6.5 0.002 0.007 0.1 2 x 720KVA DG Set

6 0.2 165 8 0.07 0.18 0.3

2 x 1020 KVA DG Set

7 0.2 170 15 0.09 0.25 0.4

* shall be kept as standby ** DG set will be used during load shut down

4.3.2.1 Diffuse Emissions

Emissions are also released from various operations of manufacturing like centrifuge,

drying, distillation, extraction etc. These emissions mainly contain volatile contents of

the material used for processing. The emissions are normally passed through vent

scrubber before releasing into atmosphere to mitigate odour. The emissions from

distillation are passed through condensers, which mitigate odour. It is proposed to

provide vent condensers in series to reactors, distillation columns, driers and centrifuge

etc. to mitigate VOC emissions release. Other vents are connected to common headers

and scrubbers. The transfer pumps shall be provided with mechanical seals. The

transfer of solvents shall be mainly by closed pipeline systems, while drum transfer is

by using air operated diaphragm pumps in closed hoods. The charging of solid raw

materials shall be by using closed hoppers to avoid dust emissions and hazard of static

electricity. Breather valves shall be provided to storage tanks. Thermal insulation and

condensers will be provided for storage tanks of low boiling point solvents. The

reactor or solvent storage tank vents when not in use shall be kept closed.

4.3.2.2 Fugitive Emissions


periodic maintenance program shall ensure integrity of equipment mitigating




management scheme as mentioned in the respective MSDS, spill control kit shall be

provided in storage, and production blocks. The fugitive emissions shall be reduced by

closed transfer and handling of all hazardous solvents and chemicals. The ventilation

system provided will reduce health impact on the employees by way of dilution of

work room air and also dispersion of contaminated air.

4.3.2.3 Air Quality Predictions (Terms of Reference No. 7(i))

Predictions of ground level concentrations of the pollutants were carried out based on

site meteorological data collected during the study period. For calculation of ground

level concentrations a grid of 5 km X 5 km with a receptor interval of 500 meters is

considered.

The composition of particulate matter was obtained from USEPA AIRCHIEF AP-42 and

the same was considered in determining the source concentration of PM10 and PM2.5 for

prediction purpose. The predicted maximum 24 hourly ground level concentrations of

Suspended Particulate Matter, PM10, PM2.5, SO2 and NOx and distance of occurrence

during different seasons of study period are presented in Table 4.5.

It may be observed that the annual predicted maximum 24 hourly GLC’s of SPM, PM10,

PM2.5, SO2 and NOx are 5.19, 2.10, 0.94, 6.89 and 4.10 μg/m3 respectively and the

maximum values are observed at a distance of 0.5 km from the center of plant site in

northeast direction. However it may be noted that the predicted values of the SO2 and

NOx are based on the assumption that the Boilers are used constantly, where as the DG

set usage is only during load shut down from TSEB.

The GLC’s are also predicted at air quality monitoring locations and the predicted

GLC’s are presented in Tables 4.6 and the cumulative concentrations at various villages

are tabulated in Table 4.7. It may be observed from the Table that the predicted results

show that the incremental rise over existing base line status of ambient air quality is

within the limits prescribed by CPCB for residential and rural areas. Hence the

control measures and height of stack is sufficient to disperse the pollutants into the

atmosphere and keeping the baseline levels within the prescribed limits. The predicted



ground level concentrations are graphically displayed for Particulate Matter, PM10,

PM2.5, SO2, and NOx respectively in Figure 4.7 – 4.11.

Table 4.5 Maximum Predicted 24 hourly GLC’s

S.No Parameter Predicted GLC (μg/m3) Distance (KM) Direction 1 SPM 5.19 0.5 NE 2 PM10 2.10 0.5 NE 3 PM2.5 0.94 0.5 NE 4 SO2 6.89 0.5 NE 5 NOX 4.10 0.5 NE

Table 4.6 Predicted GLC’s at Monitoring Locations

S.No Monitoring Location

Direction Distance (Km)

Predicted GLC (�g/m3) SPM PM10 PM2.5 SO2 NOx

1 Bontapalli SW 0.6 0.046 0.018 0.008 0.054 0.019 2 Gummadidala NW 1.8 0.003 0.001 0.001 0.003 0.001 3 Kanukunta NE 4.7 0.037 0.015 0.007 0.044 0.014 4 Srirangaram SE 5.3 0.067 0.027 0.012 0.079 0.029 5 Annaram S 3.5 0.052 0.020 0.009 0.061 0.022 6 Jinnaram SW 3.8 0.004 0.002 0.001 0.005 0.002

Reserved Forests 1 Bontapalli RF NW 0.4 0.000 0.001 0.000 0.002 0.001 2 Jinnawaram RF SW 6.5 0.000 0.000 0.000 0.001 0.000 3 Mambapur RF NW 6.5 0.000 0.000 0.000 0.001 0.000 4 Nallavalli RF NW 8 0.000 0.000 0.000 0.001 0.000 5 Nallagutta RF NW 8 0.000 0.000 0.000 0.001 0.000 6 Nagwaram RF NW 8 0.000 0.001 0.000 0.003 0.001 7 Nawabpet RF NE 8 0.000 0.001 0.000 0.002 0.001 8 Dundigil RF SE 8.5 0.000 0.000 0.000 0.001 0.000 9 Wailal RF S 8 0.000 0.001 0.000 0.002 0.001

10 Pottaguda RF SW N 0.000 0.001 0.000 0.002 0.001 11 Mangampet RF E 5 0.000 0.001 0.000 0.002 0.001 12 Narsapur RF NW 9.5 0.000 0.001 0.000 0.002 0.001 13 Royyapalli RF E 7 0.000 0.001 0.000 0.002 0.001



Table 4.7 Cumulative Concentrations at Various Villages and Reserved Forests

Station Direction Distance (Km) Baseline Concentration (μg/m3) Predicted GLC (μg/m3) Cumulative Concentration (μg/m3) PM10 PM2.5 SO2 NOx PM10 PM2.5 SO2 NOx PM10 PM2.5 SO2 NOx

1 Bontapalli SW 48 16 12 15 0.018 0.008 0.054 0.019 48.018 16.008 12.054 15.019 2 Gummadidala NW 46 16 12 14 0.001 0.001 0.003 0.001 46.001 16.001 12.003 14.001 3 Kanukunta NE 53 19 13 16 0.015 0.007 0.044 0.014 53.015 19.007 13.044 16.014 4 Srirangaram SE 42 16 12 14 0.027 0.012 0.079 0.029 42.027 16.012 12.079 14.029 5 Annaram S 41 15 11 14 0.020 0.009 0.061 0.022 41.020 15.009 11.061 14.022 6 Jinnaram SW 43 14 11 14 0.002 0.001 0.005 0.002 43.002 14.001 11.005 14.002

Reserved Forests 1 Bontapalli RF NW 0.001 0.000 0.002 0.001 0.001 0.000 0.002 0.001 2 Jinnawaram RF SW 0.000 0.000 0.001 0.000 0.000 0.000 0.001 0.000 3 Mambapur RF NW 0.000 0.000 0.001 0.000 0.000 0.000 0.001 0.000 4 Nallavalli RF NW 0.000 0.000 0.001 0.000 0.000 0.000 0.001 0.000 5 Nallagutta RF NW 0.000 0.000 0.001 0.000 0.000 0.000 0.001 0.000 6 Nagwaram RF NW 0.001 0.000 0.003 0.001 0.001 0.000 0.003 0.001 7 Nawabpet RF NE 0.001 0.000 0.002 0.001 0.001 0.000 0.002 0.001 8 Dundigil RF SE 0.000 0.000 0.001 0.000 0.000 0.000 0.001 0.000 9 Wailal RF S 0.001 0.000 0.002 0.001 0.001 0.000 0.002 0.001

10 Pottaguda RF SW 0.001 0.000 0.002 0.001 0.001 0.000 0.002 0.001 11 Mangampet RF E 0.001 0.000 0.002 0.001 0.001 0.000 0.002 0.001 12 Narsapur RF NW 0.001 0.000 0.002 0.001 0.001 0.000 0.002 0.001 13 Royyapalli RF E 0.001 0.000 0.002 0.001 0.001 0.000 0.002 0.001



ISC-AERMOD View - Lakes Environmental Software

PROJECT TITLE:

PROJECT NO.:

SCALE:

0 5 km

1:136,348

COMMENTS:

MODELER:

M/s. Team Labs and Consultants, Hyderabad

SOURCES:

7

RECEPTORS:

0

OUTPUT TYPE:

CONC

MAX:

5.19459 ug/m^3

ug/m^3PLOT FILE OF HIGH 1ST HIGH 24-HR VALUES FOR SOURCE GROUP: ALL

1.600 1.800 2.045 2.495 2.945 3.395 3.845 4.295 4.745 5.195

765

43

2

1

-10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000

-800

0-6

000

-400

0-2

000

020

0040

0060

0080

00

Figure 4.7 Isopleths Showing 24 Hourly GLC’s of SPM



ISC AERMOD View Lakes Environmental Software

PROJECT TITLE:

PROJECT NO.:

SCALE:

0 5 km

1:136,348

COMMENTS:

MODELER:


SOURCES:

7

RECEPTORS:

0

OUTPUT TYPE:

CONC

MAX:

2.10391 ug/m^3


0.604 0.854 1.104 1.354 1.604 1.854 2.104

765

43

2

1

-10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000

-800

0-6

000

-400

0-2

000

020

0040

0060

0080

00

Figure 4.8 Isopleths Showing 24 Hourly GLC’s of PM10




PROJECT TITLE:

PROJECT NO.:

SCALE:

0 5 km

1:136,348

COMMENTS:

MODELER:


SOURCES:

7

RECEPTORS:

0

OUTPUT TYPE:

CONC

MAX:

0.94779 ug/m^3


0.250 0.348 0.498 0.648 0.798 0.948

765

43

2

1

-10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000

-800

0-6

000

-400

0-2

000

020

0040

0060

0080

00

Figure 4.9 Isopleths Showing 24 Hourly GLC’s of PM2.5




PROJECT TITLE:

PROJECT NO.:

SCALE:

0 5 km

1:136,348

COMMENTS:

MODELER:


SOURCES:

7

RECEPTORS:

0

OUTPUT TYPE:

CONC

MAX:

6.89559 ug/m^3


1.850 2.346 2.996 3.646 4.296 4.946 5.596 6.246 6.896

765

43

2

1

-10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000

-800

0-6

000

-400

0-2

000

020

0040

0060

0080

00

Figure 4.10 Isopleths Showing 24 Hourly GLC’s of SO2




PROJECT TITLE:

PROJECT NO.:

SCALE:

0 5 km

1:136,348

COMMENTS:

MODELER:


SOURCES:

7

RECEPTORS:

0

OUTPUT TYPE:

CONC

MAX:

4.10994 ug/m^3


1.190 1.555 1.920 2.285 2.650 3.015 3.380 3.745 4.110

765

43

2

1

-10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000

-800

0-6

000

-400

0-2

000

020

0040

0060

0080

00

Figure 4.11 Isopleths Showing 24 Hourly GLC’s of NOX



4.3.2.4 Prediction of Concentration of Solvents in the Indoor Environment Due to

Solvent Loss and Fugitive Emissions

A simple Box Model (EVAPMOD) was used to calculate the solvent concentration in

the indoor environment. The methodology adopted was to calculate the concentration

for the product group which has the largest amount of solvent losses.

General Box Model:

Indoor air pollution models developed and used by USEPA and others consider the

conservation of air contaminant mass in a volume or "box" of workroom air. Airborne

concentrations are derived by solving the following general equation (Jay jock, 1988):

C = (Ain - Aout) / Volume of Box ---------- (1) Where

C = Concentration at time ti (assume C=0 @ t0 = 0) Ain = Mass of contaminant that went into the box during time interval ti - t0 Aout = Mass of contaminant that left the box during time interval ti - t0

The diffusion coefficient and the generation rate of the contaminant were calculated to

arrive at the airborne concentration in the environment.

For the General Ventilation Model, the overall estimate of the airborne concentration

of a contaminant is obtained by use of following equation.

Cv = (1.7*105) Ta*G M*Q*m

Where: C v = Contaminant concentration in workplace (ppm) Ta = Ambient temperature of the air (°K) G = Vapor generation rate (gm/sec) M = Molecular Weight (gm/gm-mole) Q = Ventilation rate (ft3/min) m = Mixing factor (dimensionless) Higher solvent loss and the predicted airborne concentrations of the various solvents

are tabulated in the Table 4.8.



Table 4.8 Solvent Loss and the Predicted Airborne Concentrations

S.No Name of Solvent Fugitive Loss (Kg/day)

cv, ppm TLV (ppm)

1 Toluene 80.10 25.8 200 2 Pyridine 48.20 18.1 25 3 Acetic Acid 13.70 6.8 10

4.4 Prediction of Impact on Noise Quality

The sound pressure level generated by noise source decreases with increasing

distance from the source due to wave divergence. An additional decrease in sound

pressure levels also occurs with increasing distance from the source due to

atmospheric effect or interaction with the objects in the transmission path. This is

due to excess attenuation. The sound pressure level is also affected by medium of

travel and environmental conditions. The propagation model has been devised to

take into account these factors and predict the noise levels at various distances round

a single or a multiple source. The model uses the following formula as a basis for

such predictions.

(Lob) = (Lr) - (Ldiv) - (Latm) Where (Lob) = Observed noise level at a distance R from source (Lr) = Noise level of source measured at reference distance r (Ldiv) = Loss due to divergence at distance R from source = 20 log (R/r) (Latm) = Attenuation due to atmosphere at distance R from the source. = a x R/100, where a is atmospheric attenuation coefficient in dB (A)/100m.

For hemispherical wave divergence in a homogenous loss free atmosphere (Latm) = 0.

The total impact of all sources at particular place is then estimated by adding as the contribution of noise from each of the following sources as follows; i=n (Lob)i/10 (Leq) = 10 log Σ {10 } i=1

Where n = total number of sources

The calculated noise levels are further super imposed (logarithmically) on the

background noise levels. The model assumes that the noise spectrum is mainly



centered on a spectrum of 1000 Hz and attenuation due to building materials is also at

the same frequency.

The major source of noise generation is DG set which emit noise level of maximum 90

dB (A) at a reference distance of 1m from the source. The predicted cumulative noise

levels due to the source and the existing level as calculated from the logarithmic

model without noise attenuation ranged between 55 and 75 Db (A) at distances

ranging between 8 to 15 m which falls within the plant boundary. There is no

residential area in the immediate surroundings of the plant up to a distance of 1600

meters. The impact of noise on the population in the surrounding area will be

negligible.

4.5 Prediction of Impact on Water Quality

No impact on water quality is expected due to the discharge of effluents as Zero

Liquid Discharge is envisaged. Water is essentially used for process, & utilities and

domestic purposes. The total water required for the plant is drawn from ground water

sources. The effluents generated in the plant are treated in the effluent treatment

system and reused for cooling tower makeup, and there is no usage of treated water

for on land irrigation. So the impact on water quality is negligible.

4.6 Prediction of Impact on Soil

The overall impact on soil is negligible as the treated effluent is not used for green

belt. Hazardous wastes and spillage of chemicals and wastewater may contaminate

the soil and ground water, if necessary mitigation measures are nor adopted. Green

belt development surrounding the plant site would improve the soil quality and

surrounding ecology and aesthetic appeal of the area. Trees will absorb specific air

pollutants, reduce noise pollution, reduce soil temperature, help in holding moisture

in the soil, attract more birds and overall will help in maintain the homeostasis of the

environment. As the area is presently devoid of any vegetation, avenue plantation and

greenbelt shall significantly improve the environmental quality.

4.7 Prediction of Impact on Socio Economics

The overall impact on the socio economic status is very positive, as the accrued

benefits are both direct and indirect. The direct benefits are, increase in employment,



escalation of land prices due to increased activities and improved infrastructure,

which in turn have a bearing on the productivity, industrialization and socio

economic status of the area in particular and the state in general.

4.8 Prediction of Impact on local flora and fauna

The ecological factors that are considered most significant as far as the impact on flora

and fauna concerned are:

1. Whether there shall be any reduction in species diversity?

2. Whether there shall be any habitat loss or fragmentation?

3. Whether there shall be any additional risk or threat to the rare or endangered or

endemic or threatened (REET) species?

4. Whether there shall be any impairment of ecological functions such as (i) disruption

of food chains, (ii) decline in species population and or (iii) alterations in predator-

prey relationships?

5. Whether it is possible to attain the global objectives of ‘no net loss’ of biodiversity?

6. Whether it is possible to improve the biological diversity through the proposed

activity?

There are no trees except those along the boundaries. All the trees present along the

boundaries will be protected. But on account of the proposed industry and its activity

there is no direct threat to any rare or endangered or threatened biological species as

indicated by the baseline data. The project is not going to cause any fragmentation of

habitat or disruption of food cycles or destruction of breeding grounds or blockade of

migratory routes. The major impacts of the project are mainly during construction and

subsequently on account of atmospheric pollution. The industry is required to limit it

its emissions as per the NAAQ of 2009. It has to strictly adhere to the conditions

stipulated by the regulatory bodies. The project authorities are going to take all steps

and measures in order to strictly comply with National Ambient Air Quality

Standards of 2009. The project may not have impacts on terrestrial flora and fauna.

Further, as there are no rare or endangered or threatened (RET) species within the



core or buffer area, the project does not pose any direct threat to the survival of any

rare species. Hence, the proposed project activity is unlikely to pose any additional

threat to REET species either in the core or buffer area. There shall be no diversion of

drains or canals and no filling up of ponds or lakes is anticipated.

4.9 Prediction of Impact on Vehicular Traffic

There will not be any unauthorized shop or settlements along the road connecting the

plant site. The traffic density of the adjacent high way is medium mainly of local

agro produce transport, commercial and passenger vehicle traffic. Raw materials and

finished products are transported by road using road trucks. The additional traffic

generated due to the proposed expansion shall be 2 truck trips per day. There will be

marginal increase in the traffic density.


Team Labs And Consultants 5-1

5.0 ENVIRONMENTAL MONITORING

5.1.1 Introduction

The environmental monitoring programme provides such information on which

management decision may be taken during construction and operation phases. It

provides basis for evaluating the efficiency of mitigation and pollution control

measures and suggest further actions that need to be taken to achieve the desired effect.

The monitoring includes:

(i) Visual observations;

(ii) Selection of environmental parameters at specific locations;

(iii) Sampling and regular testing of these parameters.

5.1.2 Objectives

The objectives of the environmental monitoring programme are:

• Evaluation of the efficiency of mitigation and pollution control measures;

• Updating of the actions and impacts of baseline data;

• Adoption of additional mitigation measures if the present measures are

insufficient;

• Generating the data, which may be incorporated in environmental

management plan in future projects.

5.1.3 Methodology

Monitoring methodology covers the following key aspects:

• Components to be monitored;

• Parameters for monitoring of the above components;

• Monitoring frequency;

• Monitoring standards;

• Responsibilities for monitoring;

• Direct responsibility,

• Overall responsibility;

• Monitoring costs.



Environmental monitoring of the parameters involved and the threshold limits

specified are discussed below for the proposed expansion of synthetic organic

chemicals (Bulk drug manufacturing) unit of M/s. Virchow Drugs Limited.

5.1.4 Ambient Air Quality (AAQ) Monitoring

Ambient air quality parameters recommended are PM10, PM2.5, Oxides of Nitrogen

(NOX) and Sulphur Dioxide (SO2). These are to be monitored at designated locations

starting from the commencement of construction activity. Data should be generated at

all identified locations in accordance to the National Ambient Air Quality Standards

(Table 5.1) location, duration and the pollution parameters to be monitored and the

responsible institutional arrangements are detailed out in the Environmental

Monitoring Plan.

Table 5.1 National Ambient Air Quality Standards S.No Pollutant Time

Weighted Average

Concentration in Ambient Air

Industrial, Residential, Rural and

Other Area

Ecological Sensitive Area

(Notified by Central

Government)

Methods of Measurement

1 Sulphur Dioxide (SO2)

Annual* 24 Hours**

50

80

20

80

Improved west and GaekeUltraviolet fluorescence

2 Nitrogen Dioxide (NO2)

Annual* 24 Hours**

40

80

30

80

Modified Jacob & Hochheiser (Nn-Arsenite) Chemiluminescence

3 Particulate Matter (Size Less than 10 µm) or PM10

Annual* 24 Hours**

60

100

60

100


4 Particulate Matter (Size Less than 2.5µm) or PM2.5

Annual* 24 Hours**

40

60

40

60


5 Ozone (O3) 8 hours** 1 hour**

100

180

100

180

UV Photometric Chemilminescence Chemical Method

6 Lead (Pb) Annual* 24 hours**

0.50

1.0

0.50

1.0

AAS /ICP method after sampling on EPM 2000 or equivalent filter paper ED-XRF using Teflon filter.

7 Carbon Monoxide (CO)

8 hours** 1 hour**

02

04

02

04

Non Dispersive Infra Red (NDIR) Spectroscopy



8 Ammonia (NH3)

Annual* 24 hours**

100 400

100 400

Chemilminescence Indophenol blue method

9 Benzene (C6H6) Annual* 05 05

Gas Chromotography based continuous analyzer Absorption and Desorption followed by GC analysis

10 Benzo (o) Pyrene(BaP) – Particulate Phase only,

Annual* 01 01 Solvent extraction followed by HPLC/GC analysis

11 Arsenic (As), Annual* 06 06 AAS/ICP method after sampling on EPM 2000 or equivalent filter paper

12 Nickel (Ni), Annual* 20 20 AAS/ICP method after sampling on EPM 2000 or equivalent filter paper

*Average Arithmetic mean of minimum 104 measurement in a year taken for a week 24 hourly at uniform interval.

**24 hourly/8 hourly values should meet 98 percent of the time in a year 5.1.5 Water Quality Monitoring

The physical and chemical parameters recommended for analysis of water quality

relevant are pH, total solids, total dissolved solids, total suspended solids, oil and

grease, COD, chloride, lead, zinc and cadmium. The location, duration and the

pollution parameters to be monitored and the responsible institutional arrangements

are detailed in the Environmental Monitoring Plan. The monitoring of the water quality

is to be carried out at all identified locations in accordance to the Indian Standard

Drinking Water Specification – IS 10500: 1991 (stated in Table 5.2)



Table 5.2 Indian Standard Drinking Water Specifications – IS: 10500:1991 S. No Substance or

Characteristics Requirement

(Desirable Limit)

Undesirable Effect Outside the Desirable

Limit

Perm

issi

ble

Lim

it in

the

Abs

ence

of

Alte

rnat

e So

urce

Methods of Test

(Ref. To IS)

Remarks

ESSENTIAL CHARACTERISTICS 1 Colour, Hazen

units, Max. 5 Above 5,

consumer acceptance decreases

25 3025 (Part 4) 1983

Extended to 25 only if toxic substances are not suspected, in absence of alternate sources

2 Odour Unobjectionable - - 3025 (Parts5): 1984

a) Test cold and when heated b) Test at several dilutions

3 Taste Agreeable - - 3025 (Part 7& 8) 1984

Test to be conducted only after safety has been established

4 Turbidity NTU, Max.

5 Above 5, consumer acceptance decreases

10 3025 (Part 10) 1984

-

5 pH Value 6.5 to 8.5 Beyond this range, the water will affect the mucous membrane and/or water supply system

No relaxation

3025 (Part 11) 1984

-

6 Total hardness (as CaCO3) mg/l, Max

300 Encrustation in water supply structure and adverse effects on domestic use

600 3025 (Part 21) 1983

-

7 Iron (as Fe) mg/l, Max

0.3 Beyond this limit taste/appearance are affected, has adverse effect on domestic uses and water supply struc-tures, and promotes iron bacteria

1 32 of 3025 : 1964

-

8 Chlorides (as CI) mg/l, Max

250 Beyond this limit, taste, corrosion and palatibility are affected

1000 3025 (Part 32) 1988

-



S. No Substance or Characteristics

Requirement (Desirable

Limit)


Limit

Perm

issi

ble

Lim

it in

the

Abs

ence

of

Alte

rnat

e So

urce

Methods of Test

(Ref. To IS)

Remarks

9 Residual, free chlorine, mg/l, Min

0.2 - - 3025 (Part 26) 1986

To be applicable only when water is chlorinated. Tested at consumer end. When protection against viral infection is required, it should be Min 0.5 mg/l

DESIRABLE CHARACTERISTICS 1 Dissolved

solids mg/l, Max

500 Beyond this palatability decreases and may cause gastro intestinal irritation

2000 3025 (Part 16) 1984

-

2 Calcium (as Ca) mg/l, Max

75 Encrustation in water supply structure and adverse effects on domestic use

200 3025 (Part 40) 1991

-

3 Magnesium (as Mg), mg/l, Max

30 Encrustation to water supply structure and adverse effects on domestic use

100 16, 33, 34 of IS 3025: 1964

-

4 Copper (as Cu) mg/l, Max

0.05 Astringent taste, discoloration and corrosion of pipes, fitting and utensils will be caused beyond this

1.5 36 of 3025: 1964

-

5 Manganese (as Mn) mg/l, Max

0.1 Beyond this limit taste/appearance are affected, has adverse effects on domestic uses and water supply structures

0.3 35 of 3025: 1964

-

6 Sulphate (as 200 SO4) mg/l, Max

200 Beyond this causes gastro intestinal irrita-tion when

400 3025 (Part 24) 1986

May be extended up to 400 provided (as Mg) does not exceed 30





Limit)


Limit

Perm

issi

ble

Lim

it in

the

Abs

ence

of

Alte

rnat

e So

urce

Methods of Test

(Ref. To IS)

Remarks

magnesium or sodium are present

7 Nitrate (as NO2) mg/l, Max

45 Beyond this, may cause methaemoglobinemia

100 3025 (Part 34) 1988

-

8 Fluoride (as F) mg/l, Max

1 Fluoride may be kept as low as possible. High fluoride may cause fluorosis

1.5 23 of 3025: 1964

-

9 Phenolic compounds (As C6H5OH) mg/l, Max

0.001 Beyond this, it may cause objectionable taste and odour

0.002 54 of 3025: 1964

-

10 Mercury (as Hg) mg/l, Max

0.001 Beyond this, the water becomes toxic

No relaxation

(see Note) Mercury ion analyzer

To be tested when pollution is suspected

11 Cadmium (as Cd), mg/l, Max


No relaxation

(See note) To be tested when pollution is suspected

12 Selenium (as Se), mg/l, Max


No relaxation

28 of 3025: 1964


13 Arsenic (As As) mg/l, max


No relaxation

3025 (Part 37) 1988


14 Cyanide (As CN), mg/l, Max

0.05 Beyond this limit, the water becomes toxic

No relaxation

3025 (Part 27) 1986


15 Lead (as Pb), mg/l, Max

0.05 Beyond this limit, the water becomes toxic

No relaxation

(see note) To be tested when pollution is suspected

16 Zinc (As Zn). Mg/l, Max

5 Beyond this limit it can cause astringent taste and an opalescence in water

15 39 of 3025: 1964)


17 Anionic detergents (As MBAS) mg/l, Max

0.2 Beyond this limit it can cause a light froth in water

1 Methylene-blue extraction method


18 Chromium (As 0.05 May be No 38 of 3025: To be tested when





Limit)


Limit

Perm

issi

ble

Lim

it in

the

Abs

ence

of

Alte

rnat

e So

urce

Methods of Test

(Ref. To IS)

Remarks

Cr6+) mg/l, Max

carcinogenic above this limit

relaxation 1964 pollution is suspected

19 Poly nuclear aromatic hydrocarbons (as PAH) g/1, Max

- May be carcinogenic above this limit

- - -

20 Mineral oil mg/l, Max

0.01 Beyond this limit un-desirable taste and odour after chlorination take place

0.03 Gas Chromatographic method

-

21 Pesticides mg/l, Max

Absent Toxic 0.001 - -

22 Radioactive materials: 58 of 3025:01964

-

23 a) Alpha emitters Bq/l, Max

- - 0.1 - -

24 Beta emitters pci/1, Max

- - 1 - -

25 Aluminium (as Al), mg/l, Max

200 Beyond this limit taste becomes unpleasant

600 13 of 3025:1964

-

26 Aluminium (as Al), mg/l, Max

0.03 Cumulative effect is reported to cause dementia

0.2 31 of 3025: 1964

-

27 Boron, mg/l, Max

1 - 5 29 of 3025: 1964

-

Source: Indian Standard Drinking Water Specification-IS10500:1991

5.1.6 Noise Level Monitoring

The measurements for monitoring noise levels would be carried out at all designated

locations in accordance to the Ambient Noise Standards formulated by Central

Pollution Control Board (CPCB) in 1989 (refer Table 5.3) Sound pressure levels would

be monitored on twenty-four hour basis. Noise should be recorded at a “A” weighted

frequency using a “slow time response mode” of the measuring instrument. The

location, duration and the noise pollution parameters to be monitored and the



responsible institutional arrangements are detailed in the Environmental Monitoring

Plan (Table 5.3)

Table 5.3 Noise level standards (CPCB) Type Noise level for Day Noise level for Industrial area 75 70 Commercial area 65 55 Residential area 55 45 Silence zone 50 40 Day time - 6.00 am - 9.00 pm (15 hours)

The monitoring plan along with the environmental parameters and the time frame is

presented in the Table 5.4.

Table 5.4 Environmental Monitoring Plan (Terms of Reference No. 7(xii) & B(4) S.No Particulars Monitoring

Frequency Standards Duration

of Sampling

Important monitoring parameters

Ambient Air Quality Monitoring 1 Industry

Main Gate, Domadugu Bonthpally Villages

Quarterly Air (Prevention and Control of Pollution) Rules, CPCB, 1994

24 hrs PM10, PM2.5, SO2, Nox, & VOC

2 Work Place Monitoring : Production blocks 2 locations, Solvent Tankfarm, and ETP area

Quarterly 8 hr SPM, VOC

Stack Emissions Monitoring 1 Utility Stacks : 2 nos. Coal

fired boiler, and 2 no.s DG sets.

Quarterly Air (Prevention and Control of Pollution) Rules, CPCB, 1994

-- PM, SO2, Nox , recommended methods of CPCB.

Water Quality Monitoring 1 Process water Daily Water Quality

standards by CPCB

Grab pH, TDS, SS, BOD, COD and Oil & Grease Hardness, , chlorides, using APHA or BIS analytical methods.

2 Effluents Stream wise Quarterly Grab pH, TDS, SS, BOD, COD using APHA or BIS analytical methods.

3 Treated effluent after ZLD Daily Grab pH, TDS, TSS, COD, BOD and Oil and Grease using APHA or BIS analytical methods.

Noise Quality Monitoring 1 Noise Levels at 2 Locations

with in plant site and 2 locations outside the plant site, Domadugu Bonthpally Villages

Quarterly Noise standards by CPCB

24 hrs Equivalent Noise levels in dB(A)



Soil Quality Monitoring 1 Soil - locations within the

site; storage area, near production blocks (2no.s), HW Storage area and ETP area.

Once a year pH, EC, CEC, Lead, Moisture, Texture, Bulk Density etc.

5.1.7 Responsibility of Monitoring And Reporting System

The overall responsibility of monitoring the above parameters shall lie with the

management of Virchow Drugs Limited. The maintenance/environment wing shall be

responsible for day to day monitoring of effluent, raw water and treated water quality.

The Ambient air quality, Stack emissions, soil, noise and water quality shall be

monitored by either third party or by the Environment management division of the

unit.

Records shall be maintained for the analysis of raw effluents and treated effluents,

ambient air quality data, stack emissions monitoring results, micrometeorological data

and noise levels. These records are not only required for the perusal of the Pollution

Control Board authorities but also to derive at the efficiencies of the pollution control

equipment as the objective of the project proponent is not only compliance with

statutory regulations, but also a serious commitment towards clean environment.

The industry shall maintain the records as per the hazardous waste regulations and

EPA regulations and apply for the annual consents for air and water, and renewal of

authorization for the storage of hazardous waste as per Hazardous Waste (Handling &

Management) Rules, 1989. The records of hazardous waste manifest will be

maintained.

Reporting system provides the necessary feedback for project management to ensure

quality of the works and that the management plan in implementation. The rationale

for a reporting system is based on accountability to ensure that the measures proposed

as part of the Environmental Management Plan get implemented in the project.

5.2 Environmental Monitoring Budget

The environmental budget for the various environmental management measures in the

EMP is detailed in Table 5.5. There are several other environmental issues that have



been addressed as part of good engineering practices, the costs for which have been

accounted for in the Engineering Costs. Moreover, since environmental enhancements

have not been finalized at this stage, the table projects the typical costs unit wise.

Table 5.5 Environmental Monitoring Budget Particulars Monitoring

Frequency Unit Cost

Rs. Annual Cost

Rs. Ambient Air Quality Monitoring Monthly 4500 162000 Work Place Monitoring Monthly 2000 96000 Stack Emissions Monitoring Monthly 2700 64800 DG Set Stack Emissions Monitoring Quarterly 2700 21600 Process water Daily 500 165000 Effluents - Stream wise Quarterly 600 4800 Treated effluent (ETP water) Daily 600 198000 Noise Level Monitoring Quarterly 1000 16000 Soil Quality Once a year 2000 10000 Total (Rs.) 738200



6.0 RISK ASSESSMENT AND DAMAGE CONTROL 6.0 INTRODUCTION

This chapter presents the risk assessment study results for the plant operations, transport

and storage of raw materials, and identifies maximum credible accident scenarios to draw

the emergency management plan addressing various credible scenarios identified.

6.1. OBJECTIVES AND SCOPE

The production of Bulk drugs involves usage of many chemicals which are both

hazardous and toxic in nature. The risks associated with the pharmaceutical / chemical

industry are commensurate with their rapid growth and development. Apart from their

utility, chemicals have their own inherent properties and hazards. Some of them can be

flammable, explosive, toxic or corrosive etc. The whole lifecycle of a chemical should be

considered when assessing its dangers and benefits. In order to ensure the health and

safety of persons at or near the facilities, Govt. has approved some regulations. The

regulation requires Employers to consult with employees in relation to:

- Identification of major hazards and potential major accidents

- Risk assessment

- Adoption of control measures

- Establishment and implementation of a safety management system

- Development of the safety report

The involvement of the employees in the identification of hazards and control measures

enhances their awareness of these issues and is critical to the achievement of safe

operation in practice. In order to comply with regulatory authorities, M/s Virchow Drugs

Limited have entrusted Team Labs and Consultants, Hyderabad to review and prepare

Hazard analysis and Risk assessment for their facility along with an approach to on-site

emergency preparedness plan as required under the acts and rules. (Manual on emergency

preparedness for chemical hazards, MOEF, New Delhi). In this endeavor, the methodology

adopted is based on



• visualizing various probable undesirable events which lead to major accidents

• detailed and systematic assessment of the risk associated with each of those

hazards, including the likelihood and consequences of each potential major accident

event; and

• identifying the technical and other control measures that are necessary to reduce

that risk to a level that is as low as reasonably practicable

The strategy to tackle such emergencies, in-depth planning and person(s) or positional

responsibilities of employees for implementation and coordination of timely and effective

response measures are described in onsite detail in Emergency Plan.

6.2 PROJECT DETAILS: The project site is located at Sy. No. 639 (Part), IDA Bonthapally, Jinnaram Mandal, Medak

District, Telangana. The site is situated at intersection of 78021’15.06” (E) and latitude

17039’24.70” (N). The site is surrounded by road connecting Jinnaram and Bonthappay in

north direction, SSI Company in south direction, M/s. Samkrg Pistons and Rings Ltd., in

east direction and open land in west direction. The nearest habitation from the site is

bonthapally at a distance of 1.2 Km in northeast direction. The main approach road is

Hyderabad – Narsapur passing at a distance of 2 km in east direction. The nearest railway

station is Medchal at a distance of 12.87 km in southeast direction and the nearest airport is

located at a distance of 48 km in southeast direction. Medchal town is located at a distance

of 12.8 km in southeast direction.There are no major water bodies within the study area.

Bonthapalle RF at a distance of 0.4 Km in northwest, Jinnawaram RF at a distance of 6.5

Km in southwest, Mangapet RF at a distance of 5 Km in east, Royyapalli RF at a distance

of 7 Km in east, Wailal RF at a distance of 8 Km in south, Dundigal RF at a distance of 8.5

Km in southeast, Nagawaram RF at a distance of 8 Km in northwest, Mambapur RF at a

distance of 6.5 Km in northwest, Nallavalli RF at a distance of 8 Km in northwest,

Pottaguda RF at a distance of 9 Km in southwest directions respectively. The

manufacturing capacity of the proposed expansion Chemicals are presented in Table 6.1

and chemical inventory is presented in Table 6.3



Table 6.1 Manufacturing Capacity

S.No Name of Product Capacity (TPM) Permitted After Expansion




Table 6.2 List of By-Products – After Expansion S.No Name of product Name of By -Product Capacity


Dil . Acetic acid 2850 85.5

Table 6.3 List of Raw Materials and Inventory Terms of Reference No. 3(iv) & (v)) S.No Name of the raw

material Max Storage

Quantity (Tons)

Physical Form

Type of Hazard

Mode of Storage

1 2-Amino pyridine 7.5 Solid Irritant Bags 2 Acetic acid 23.0 Liquid Corrosive Storage Tank 3 Acetyl Sulfanilyl chloride 8.0 Powder Corrosive Bags 4 Activated carbon 1.0 Solid Irritant Bags 5 Ammonia 5.0 Liquid Corrosive Drums 6 Citric acid 0.1 Liquid Corrosive Drums

7 Ethylene diamine tetra acetic acid (EDTA)

0.1 Liquid Flammable Drums

8 Hydrochloric acid 19.0 Liquid Corrosive Storage Tank 9 Hydrose 0.2 Powder Non-Hazard Bags 10 Pyridine 8.0 Liquid Flammable Drums 11 Salicylic acid 3.0 Liquid Corrosive Drums 12 Sodium hydroxide 20.0 Liquid Corrosive Storage Tank 13 Sodium nitrate 2.0 Powder Corrosive Bags 14 Sulfuric acid 30.0 Liquid Corrosive Storage Tank 15 Toluene 12.0 Liquid Flammable Storage Tank



6.3 PROCESS DESCRIPTION

The manufacturing process for all the products is presented in Chapter 2. (Page No. 2-2 to

2-8) of the report.

6.4 PLANT FACILITIES

The existing manufacturing facility provided with

1) Production blocks 2) Utilities 3) Quality control, R&D lab 4) Effluent treatment plant

5) Warehouses 6) Tankfarm area 7) Administrative Office

The production facilities are designed for proper handling of materials and machines.

Safety of operators, batch repeatability and process parameter monitoring shall be the

major points of focus in the design of facility. The current Good Manufacturing

Practices (GMP) guidelines shall be incorporated as applicable to pharmaceutical

facilities.

6.4.1 Production Blocks:

Production blocks consist of SS and glass lined reactors, storage tanks, shell & tube heat

exchangers, evaporators, packed columns, centrifuges, filter presses, crystallizers, layer

separators etc. The area shall be provided with proper concealed drainage facility and

all process facilities shall be performed under protective environment.

6.4.2 Utilities:



boiler. The required steam is drawn from proposed 4 TPH coal fired boiler and existing

3 TPH boiler, while the existing 1TPH coal fired boiler will be dismantled after

expansion. No additional DG sets are proposed, existing DG sets of capacity 500 and

200 KVA shall be kept as standby during load shut down. The list of utilities is

presented in the following Table 6.4.



Table 6.4 List of Utilities S.No Description Capacity



1 x 500 KVA 1 x 200 KVA


6.4.3 Quality Control, R&D Lab:

The QC department comprise of an in-process lab with instruments like HPLC, GC etc

maintained by highly qualified and trained people. The activities include:

• In-process quality check during manufacturing • Validation of facilities • Complaint handling

Also a process development laboratory for in-house process development, initial

evaluation of process technology in case of technology transfer, back-up for production

department to address any issues arising during commercial production

6.4.4 ETP and Solid waste storage:

The total effluents segregated into two streams High COD/ TDS and Low COD/ TDS

streams. These effluents are treated in Zero Liquid Discharge system and the treated

effluents are reused for cooling towers make-up and boiler.

6.4.5 Ware Houses:

The plant have sufficient storage facility for safe handling of raw materials. All solid

raw materials shall be stored in marked areas with proper identification. Liquid raw

materials and solvents like which are available in drums will be stored according to

material compatibilities and flammability. Adequate fire fighting facilities shall be

provided as per NFPA norms.



6.4.6 Tank Farm Area:

A separate tank farm area shall be provided for storing liquid raw materials, especially.

Solvents with high inventory and also for toxic, corrosive chemicals. Dykes shall be

provided to ensure safety in case of tank failure.

6.4.7 Administrative Office:

An Administrative office provided at the entrance of the factory to ensure the entry of

authorized personnel only into the premises.

6.4.8 Water Sump:

Water sump of 30 m3 capacity provided for fire fighting in case of emergencies.

6.4.9 House Keeping:

A regular housekeeping schedule with adequate preventive maintenance shall be

ensured so that the plant is consistently maintained as per GMP standards.

6.4.10 Facility layout and design:

The layout of all the various areas required for the facility, as mentioned above is

considered. In laying out the above areas, isolation of the various process areas from the

utilities and non-process areas is considered in view of both containment and cGMP. A

tentative plant layout is shown in Fig 6.1.



Fig 6.1 Plant Layout of Virchow Drugs Limited



6.5 Hazard Analysis and Risk Assessment (Terms of Reference No. 3(ix))

6.5.1 Introduction.

Hazard analysis involves the identification and quantification of the various hazards

(unsafe conditions) that exist in the plant. On the other hand, risk analysis deals with the

identification and quantification of risks, the plant equipment and personnel are exposed

to, due to accidents resulting from the hazards present in the plant.

Hazard and risk analysis involves very extensive studies, and requires a very detailed

design and engineering information. The various hazard analysis techniques that may be

applied are hazard and operability studies, fault-tree analysis, event-tree analysis and

failure and effects mode analysis.

Risk analysis follows an extensive hazard analysis. It involves the identification and

assessment of risks; the neighboring populations are exposed to as a result of hazards

present. This requires a thorough knowledge of failure probability, credible accident

scenario, vulnerability of population's etc. Much of this information is difficult to get or

generate. Consequently, the risk analysis is often confined to maximum credible accident

studies.

In the sections below, the identification of various hazards, probable risks, maximum

credible accident analysis, consequence analysis are addressed which gives a broad

identification of risks involved in the plant.

6.5.2 Hazard Identification

The Hazard identification process must identify hazards that could cause a potential

major accident for the full range of operational modes, including normal operations,

start-up, shutdown, and also potential upset, emergency or abnormal conditions.

Employers should also reassess their Hazard identification process whenever a

significant change in operations has occurred or a new substance has been introduced.

They should also consider incidents, which have occurred elsewhere at similar facilities

including within the same industry and in other industries.



Hazard identification and risk assessment involves a critical sequence of information

gathering and the application of a decision-making process. These assist in discovering

what could possibly cause a major accident (hazard identification), how likely it is that a

major accident would occur and the potential consequences (risk assessment) and what

options there are for preventing and mitigating a major accident (control measures).

These activities should also assist in improving operations and productivity and reduce

the occurrence of incidents and near misses.

The chemical and process industries have been using a variety of hazard identification

techniques for many years, ranging from simple screening checklists to highly structured

Hazard and Operability (HAZOP) analysis. Each technique has its own strengths and

weaknesses for identifying hazards. It is impossible to compare hazard identification

techniques and come to any conclusion as to which is the best. Each technique has been

developed for a specific range of circumstances taking many factors into account

including the resources required to undertake the analysis, expertise available and stage

of the process. While HAZOP is primarily a tool for hazard identification, the HAZOP

process can also include assessment of the causes of accidents, their likelihood and the

consequences that may arise, so as to decide if the risk is acceptable, unacceptable or

requires further study.. Moreover, a formal guidance for applying this technique is

available. Collaboration between management and staff is fundamental to achieving

effective and efficient hazard identification and risk assessment processes.

After identifying hazards through a qualitative process, quantification of potential

consequences of identified hazards using simulation modeling is undertaken. Estimation

of probability of an unexpected event and its consequences form the basis of

quantification of risk in terms of damage to property, environment or personnel.

Therefore, the type, quantity, location and conditions of release of a toxic or flammable

substance have to be identified in order to estimate its damaging effects, the area

involved, and the possible precautionary measures required to be taken.



Considering operating modes of the facility, and based on available resources the

following hazard identification process chosen are:

a) Fire Explosion and Toxicity Index (FETI) Approach; b) HAZOP studies; c) Maximum Credible Accident and Consequence Analysis (MCACA); d) Classification of Major Hazard Substances; e) Manufacture Storage and Import of Hazardous Chemical Rules, 1989 (GOI Rules,

1989); f) Identification of Major Hazardous Units.

The interpretation of “The Manufacture Storage and Import of Hazardous chemicals”

issued by the Ministry of Environment and Forests, GOI, which guides the preparation of

various reports necessary for safe handling and storage of chemicals shows that the

present project requires preparation of safety reports before commencing operation and

risk assessment is not mandatory. The applicability of various rules is presented in

Table 6.5.

Table 6.5 Applicability of GOI Rules to Storage/Pipeline S. No

Chemical Inventory KL

Threshold Quantity (T) For Application of Rules Applicable Rules 5,7-9, 13-15 10-12

1 Acetic acid 23.0 1500 10000 4 (1) (a), (2), 5,15 2 Hydrochloric acid 19.0 1500 10000 4 (1) (a), (2), 5,15 3 Sodium hydroxide 20.0 1500 10000 4 (1) (a), (2), 5,15 4 Sulfuric acid 30.0 1500 10000 4 (1) (a), (2), 5,15 5 Toluene 12.0 1500 10000 4 (1) (a), (2), 5,15

6.5.3 Fire & Explosion Index (F & EI):

6.5.3.1 Methodology

Dow Chemical Company issued a guideline for hazard determination and protection. By

this method a chemical process unit is rated numerically for hazards. The numerical

value used is the Fire and Explosion Index (F&EI) which is most widely used for hazard

evaluation in chemical process industries.

The guide applies to process unit only and not to auxiliary units such as power

generating stations, plant water systems, control rooms, fired heaters, structural



requirements, corrosive nature of material handled and personal safety equipment. These

are regarded as basic features that do not vary according to the magnitude of the fire and

explosion hazard involved. The guide also does not cover the processing and handling of

explosives such as dynamite, TNT etc.

Computation of F&EI

The F&EI is calculated as a product of Material factor, General process hazard factor, and

special process hazard factor The Material factor is a measure of the intrinsic rate of

potential energy release from fire or explosion of most hazardous material or mixture of

materials present in significant quantity, whether it is raw material, intermediate,

product, solvent etc, by combustion or chemical reaction. “In significant quantity” here

means such quantity that the hazard represented by the material actually exists. The

National Fire Protection Agency of USA (NFPA) have specified standard values for

material factor which should be used for F&EI calculations and are available in Dow’s

Hazard Classification Guide. In case it is not readily available, it can be calculated using

the heat of combustion, flammability indices etc.

General process hazards are factors that play a primary role in determining the

magnitude of loss of incident. It takes into account the nature of the reaction, ventilation

of the unit, accessibility of the unit, drainage facilities etc., Special process hazards are

factors that contribute primarily to the probability of a loss of incident. They consist of

specific process conditions that have shown themselves to be major causes of fire and

explosion incidents. It takes into account toxicity of the material, operating pressure,

operation near flammable range, quantity of material, joints and packing, use of hot oil

exchange system etc., The F&EI index is calculated as a product of Material factor,

General process hazard factor, and Special process hazard factor.

Hazard Ranking The hazard ranking based on F&EI value is presented in Table 6.6.



Table 6.6 Degree of Hazard for F&EI F&EI Index Range Degree of Hazard

1 – 60 Light 61 – 96 Moderate

97 – 127 Intermediate 128 – 158 Heavy

159 & above Severe

The estimated values of F&EI and hazard ranking are given in the Table 6.7. The radius

of exposure is determined by 0.26 meter x respective F&EI. The estimated values of F&EI

reflect light hazard in view of the low volume of chemicals.

The fire and explosion index evaluation can be very useful in developing plant layouts or

adding equipment and buildings to existing plants. Evaluation of the F&EI calculations

and layout considerations will result a safe, operable, maintainable and cost-effective

arrangement of equipment and buildings.

Table 6.7 Fire & Explosion Index for Tank farm S. No. Name of the Solvent Fire &

Explosion Index (F1*F2*MF)

Radius of Exposure (m)

F&EIx0.26

Degree of Hazard

1 Acetic Acid 61.2 15.91 Moderate 2 Toluene 81.28 21.13 Moderate

The storage is a small capacity facility and accordingly the F& E index value is found to be

moderate reflecting the threshold limits as prescribed in MSHC rules. Both MSHC rules

and F & E index indicate that the present facility does not require a detailed risk

assessment.

6.5.4 Hazard and Operability Study (HAZOP)

Hazard and Operability Study (HAZOP) is a highly structured and detailed technique,

developed primarily for application to chemical process systems. A HAZOP can generate

a comprehensive understanding of the possible ‘deviations from design intent’ that may

occur. However, HAZOP is less suitable for identification of hazards not related to

process operations, such as mechanical integrity failures, procedural errors, or external



events. HAZOP also tends to identify hazards specific to the section being assessed, while

hazards related to the interactions between different sections may not be identified.

However, this technique helps to identify hazards in a process plant and the operability

problems. It is performed once the engineering line diagrams of the plant are made

available. It is carried out during or immediately after the design stage. The purpose of

the study is to identify all possible deviations from the way the design/operation is

expected to work and all the hazards associated with these deviations. A multi-

disciplinary team was constituted with chemical, mechanical and instrumentation

engineers, R&D chemist and production manager. It is important to keep the team small

enough to be efficient, while retaining a sufficient spread of skills and disciplines for all

aspects of the study to be covered comprehensively. The group discussion is facilitated

by a Chairman and the results of the discussion are recorded by a Secretary. Every

investigation must be led by Chairman who is familiar with the HAZOP study technique,

which is primarily concerned with applying, controlling the discussions and stimulating

team thinking.

The preparative work for HAZOP studies consisted of four stages i.e., obtaining the data,

converting into usable form, planning the sequence of the study and arranging the

necessary meetings. The documents referred to for the study include process description,

process flow diagrams, P&I diagrams plant layout, operating manuals including startup

& shutdown, safety instructions etc., The parameters such as temperature, pressure, flow,

level were investigated for deviation and hazard situations are identified.

Some basic definitions of terms frequently used in HAZOP studies are deviation, causes,

consequences and guide words etc., Deviations are departures from the design intent

which are discovered by systematically applying the guide words. Causes are the reasons

why deviations might occur. Consequences are the reasons why deviations should they

occur. Guide words are simple words used to understand a particular plant section in

operating condition in order to guide and simulate the creative thinking process and so



discover deviations. NO, less, more, as well as, part of, reverse, other than are guide

words used.

Potential problems as represented by the consequences of the deviation should be

evaluated as they arise and a decision reached on whether they merit further

consideration or action. Except for major risk areas where a fully quantitative assessment

is required this decision is made semi-quantitatively on the consequence (usually scaled

as trivial, important or very probable).

6.5.5 Hazard Factors

A study of past accident information provides an understanding of failure modes and

mechanisms of process and control equipment and human systems and their likely effects

on the overall plant reliability and safety.

Some of the major contributing factors for accidents in chemical industries are:

S. No Contributing Factor Percent Loss 1 Equipment design faults 41 2 Process design faults 10 3 Operator errors 31 4 Maintenance deficiencies 12 5 Material hazards 6

A study by AIChE (1972) indicates that majority of equipment of component failures

involve compressors, furnaces and heat exchangers as there are lesser opportunities to

take them off for maintenance. The frequency of equipment or component failures is

observed as follows:

S. No Equipment Frequency (%)

1 Compressors 30 2 Furnaces 18 3 Heat Exchangers 17 4 Process Vessels 18 5 Others 17



However, failures of storage vessels and those during transportation have been reported

more frequently than cases of plant failures. The failure rate of various equipment in a

typical power plant is provided in the following table.

Equipment Failure Rates Failure rate Failures 10-6/h Electric motors (general) 10 Transformers (<15 kV) 0.6 (132-400k V) 0.7 Circuit breakers (general, <33k V) 2 (400kV) 10 Pressure vessels (general) 3 (High standard) 0.3 Pipes 0.2 Pipe joints 0.5 Ducts 1 Gaskets 0.5 Bellows 5 Diagrams (metal) 5 (Rubber) 8 Unions and junctions 0.4 Hoses (heavily stressed) 40 (Lightly stressed) 4 Ball bearings (heavy duty) 20 (Light duty) 10 Roll bearings 5 Sleeve bearings 5 Shafts (heavily stressed) 0.2 (Lightly stressed) 0.02 Relief valves leakage 2 Blockage 0.5 Hand- operated valves 15 Control valves 30 Ball valves 0.5 Solenoid valves 30 Rotating seals 7 Sliding seals 3 ‘O’ring seals 0.2 Couplings 5



Failure rate Failures 10-6/h Belt drives 40 Spur gears 10 Helical gears 1 Friction clutches 3 Magnetic clutches 6 Fixed orifices 1 Variable orifices 5 Nozzle and flapper assemblies: Blockage 6 Breakage 0.2 Filters: blockage 1 Leakage 1 Rack-and-pinion assembles 2 Knife-edge fulcrum: wear 10 Springs (heavily stressed) 1 (Lightly stressed) 0.2 Hair springs 1 Calibration springs: creep 2 Breakage 0.2 Vibration mounts 9 Mechanical joints 0.2 Grub screws 0.5 Pins 15 Pivots 1 Nuts 0.02 Bolts 0.02 Boilers (all types) 1.1 Boilers feed pumps 2.5 Cranes 7.8

6.5.6 Common Causes of Accidents

Engineering and Instrumental

Based on the analysis of past accident information, common causes of major chemical

plant accidents are identified as:

• Poor house keeping • Improper use of tools, equipment, facilities • Unsafe or defective equipment facilities • Lack of proper procedures • Improving unsafe procedures



• Failure to follow prescribed procedures • Jobs not understood • Lack of awareness of hazards involved • Lack of proper tools, equipment, facilities • Lack of guides and safety devices • Lack of protective equipment and clothing

Failures of Human Systems

An assessment of past chemical accidents reveals human factor to be the cause for over

60% of the accidents while the rest are due to other plant component failures. This

percentage will increase if major accidents alone are considered for analysis. Major

causes of human failures reported are due to:

• Stress induced by poor equipment design, unfavorable environmental conditions,

fatigue, etc.

• Lack of training in safety and loss prevention.

• Indecision in critical situations.

• Inexperienced staff being employed in hazardous situations.

Often, human errors are not analyzed while accident reporting and accident reports only

provide information about equipment or component failures. Hence, a great deal of

uncertainty surrounds analysis of failure of human systems and consequent damages.

The number of persons/materials are potentially exposed to a specific hazard zone is a

function of the population density and distribution near the accident location. The failure

rate data and ignition sources of major fires are presented in the following Tables 6.8 and

6.9.

Table 6.8 Failure Rate Data

S.No Item International Data 1. Process Controllers 2.4 x 10-5 hr-5 2. Process control valve 2.0 x 10-6 hr-1 3. Alarm 2.3 x 10-5 hr-1



4. Leakage at biggest storage tank 5.0 x 10-5 yr-1 5. Leakage of pipe line 1 x 10-7 m-1 yr-1 6. Human Failure 1 x 10-4 (demand)-1

Table 6.9 Ignition Sources of Major Fires S.No Ignition Source Percent 1. Electrical (wiring of motors) 23% 2. Smoking 18% 3. Friction 10% 4. Over heated material 8% 5. Burner flames 7% 6. Combustion sparks 5% 7. Spontaneous ignition 4% 8. Cutting & welding 4% 9. Exposure (fires jumping into new areas) 3% 10. Incendiarism (fires maliciously set) 2% 11. Mechanical sparks 2% 12. Molten substances 1% 13. Chemical actions 1% 14. Static sparks 1% 15. Lightening 1% 16. Miscellaneous 1%

6.6 Maximum Credible Accident and Consequence Analysis (MCACA)

The potential hazards due to toxic and inflammable nature of the raw materials, process

streams and products could be quantified. However, it is necessary to carry out a hazard

analysis study to visualize the consequences of an unexpected release from chemical

plant, which consists of a number of process units and tank farm facilities. The present

study provides the quantified picture of the potential hazards and their consequences



6.6.1 Methodology

MCACA aims at identifying the unwanted hazardous events, which can cause maximum

damage to plant and personnel. At the first instance, all probable accident scenarios are

developed. Scenarios are generated based on properties of chemicals, physical conditions

under which reactions occur or raw materials stored, as well as material strength of

vessels and conduits, in-built valves and safety arrangements, etc. Creating a scenario

does not mean that it will occur, only that there is a reasonable probability that it could. A

scenario is neither a specific situation nor a specific event, but a description of a typical

situation that covers a set of possible events or situations.

This is the basis of the risk study; it tells us what may happen so that ways and means of

preventing or minimizing the possibility can be devised. The next step is estimation of

the probability of each accident scenario. A credible accident is one within the realm of

possibility and is likely to be severe enough to cause significant damage. This concept

comprises of two parameters- probable damage caused by an accident and probability of

occurrence of an accident .There may be types of accidents that may occur frequently, but

would cause very little damage. And there may be other types that may cause great

damage, but would have a very low probability of occurrence. Both are important and

need to be considered, even if they are later discarded. A host of probable accident

scenarios are visualized examined and credibility of probable events is established based

on engineering judgment, past accident data and expertise in the field of risk analysis.

The following steps are involved in identifying the maximum credible accident scenarios.

a. A detailed study of the process and plant information including process flow diagrams

and piping & instrumentation diagrams.

b. Hazard classification of chemicals, operations and equipment.

c. Identification of representative failure cases of vessels and pipelines and the resulting

release scenarios

d. Establishment of credibility of visualized scenarios based on past accident data.



6.6.2 Identification of Vulnerable Areas

The unit operations in the process and storage areas involve mass and energy transfer

operations to effect the necessary physical changes. Nature of chemicals and the

operating conditions create special hazardous situations. In the present case the chemicals

handled are flammable and toxic in nature. With these factors in mind a thorough

examination of the process information is carried out and a list of inventories of the

hazardous chemicals is prepared to identify the hazardous situations. Based on the raw

material consumptions determined from the pilot scale studies, experience in handling

commercial scale processes and logistics in procurement of raw materials, the inventories

to be maintained for each of the raw material and its mode of storage is determined. High

inventory liquid raw materials like solvents are usually stored in tank farms, while solids

and other low inventory liquids are stored in ware house based on compatibility,

reactivity, toxicity etc. with appropriate safety and fire fighting facilities to handle any

kind of emergencies.

6.6.3 Representative Accident Scenarios

A study of past accidents, which took place in similar process units and the present plant,

provides reasons and course of accidents and there by focusing on most critical areas. A

thorough examination of engineering details indicated many possible scenarios like

gasket leak, pinholes in pipes & vessels apart from rupture of pipelines & vessels and

catastrophic failure of vessels. Heat radiation damage distances for Pool fire was

considered.

Failure Frequency:

The release scenarios considered above can be broadly divided in to two categories

(i) Catastrophic failures which are of low frequency and

(ii) Ruptures and leaks which are of relatively high frequency

Vapor or liquid release from failure of gasket, seal and rupture in pipe lines and vessels

fall in second category whereas catastrophic failure of vessels and full bore rupture of

pipe lines etc., fall in to first category. Typical failure frequencies are given in Table 6.10.



Table 6.10 General Failure Frequencies Item Mode of failure Failure frequencies Pressure Vessel

Serious leak 1.0*10-5/Year Catastrophic 3.0*10-6/Year

Pipe lines =50 mm dia

Full bore rupture 8.8*10-7/m.year Significant leak 8.8*10-6/m.year

>50 mm =150 mm dia


>150 mm dia


Hose Rapture/Failure 4.0*10-5/hr Unloading arm Rapture/Failure 3.0*10-8/hr Check valve Failure on demand 1.0*10-4/on demand motor operated valve Failure on demand 1.0*10-3/ on demand Flange Leak 3.0*10-4/ Year Pump seal Leak 5.0*10-3/ Year Gasket failure Failure 5.0*10-5/ Year Process safety valve(PSV)

Lifts heavily 4.0*10-3/ Year Blocked 1.0*10-3/ Year Lifts lightly 6.0*10-2/ Year

6.7 CONSEQUENCE ANALYSIS

The accidental release of hazardous chemicals leads to subsequent events, which actually

cause the damage. The damages are of three types.

1) Damage due to heat radiation. 2) Damage due to Over pressure effects subsequent to explosion 3) Damage due to toxic effects

The type of damage and extent of damage depends on nature of chemical, the conditions

of release, atmospheric conditions and the subsequent events. The sequence of probable

events following the release of a hazardous chemical is schematically shown in Figure

6.2. The best way of understanding and quantifying the physical effects of any accidental

release of chemicals from their normal containment is by means of mathematical

modeling. This is achieved by describing the physical situations by mathematical

equations for idealized conditions and by making corrections for deviation of the

practical situations from ideal conditions. In the present study ALOHA software from

USEPA. These models for various steps are described in the following sub-sections.



6.7.1 Release Models and Source strength

This depends on the nature of failure of the unit and the content of the unit and operating

temperature and pressure of the unit. The release may be instantaneous due to total

failure of storage unit or continuous due to leakage or rupture of some component of the

storage facility. The material discharged may be gas or liquid or the discharge could be

manifested through two phase flow. The models that are used to calculate the quantity of

liquid/vapor released are:

Fig 6.2 Steps in Consequence Calculations

The following criteria tables present heat radiation intensities (Table 6.11), radiation

exposure and lethality (Table 6.12), and damage due to peak over pressure is presented

in Table 6.13.



Table 6.11 Damage Due to Incident Radiation Intensities S. No Incident

Radiation (KW/m2)

Type of Damage Intensity Damage to Equipment Damage to the People

1 37.5 Damage to process Equipment 100% lethality in 1 min.

1% lethality in 10 sec.

2 25.0 Minimum energy required to ignite wood at indefinitely long exposure without a flame

50 % lethality in 1min.

Significant injury in 10 sec.

3 19.0 Maximum thermal radiation intensity allowed n thermally unprotected adjoining equipment.

---

4 12.5 Minimum energy to ignite with a flame, melts plastic tubing

1% lethality in 1 min.

5 4.0 -- Causes pain if duration is longer than 20 sec, however blistering is unlikely ( First degree burns)

6 1.6 -- Causes no discomfort on Longer exposure

Source: Techniques for Assessing Industrial Hazards by World Bank

Table 6.12 Radiation exposure and lethality

Radiation Intensity (KW/m2)

Exposure Time (seconds)

1% Lethality Degree Burns

1.6 -- 0 No Discomfort even after longer exposure

4.5 20 0 1st 4.5 50 0 1 st 8.0 20 0 1 st 8.0 50 <1 3 rd 8.0 60 <1 3 rd

12.0 20 <1 2 nd 12.0 50 8 3 rd 12.5 -- 1 -- 25.0 -- 50 -- 37.5 -- 100 --



Table 6.13 Damage Due to Peak Over Pressure Human Injury Structural Damage

Peak Over Pressure (bar)

Type of Damage Peak over Pressure (bar)

Type of Damage

5 – 8 100% lethality 0.3 Heavy (90%Damage) 3.5 – 5 50% lethality 0.1 Repairable (10%Damage) 2 – 3 Threshold lethality 0.03 Damage of Glass

1.33 – 2 Severe Lung damage 0.01 Crack of Windows 1 – 11/3 50% Eardrum

rupture - -

Source : Marshall, V.C.(1977)’ How lethal are explosives and toxic escapes.

6.7.2 Results of Consequence Analysis

The damages due to the accidental release of chemicals are of three types.

a) Damage due to heat radiation

b) Damage due to Over pressure effects subsequent to explosion

c) Damage due to Toxic effects

The consequence analysis for the identified scenarios is carried out using software based

on Yellow book of TNO.

6.7.2.1 Analysis of Hazardous Scenarios

The hazardous chemicals involved are stored within the threshold limits of storage and

hence few representative chemicals mainly solvents were studied.

6.7.2.1.1 Heat radiation effects

When a non-boiling liquid spills, it spreads into a pool. The size of the pool depends on

the availability of the bund and obstacles. The heat load on objects outside a burning pool

of liquid is calculated with the heat radiation model. The average heat radiation intensity,

the diameter-to-height ratio dependent on the burning liquid, geometric view, distance

from the fire, relative humidity of air, horizontal or vertical orientation of the object

radiated with respect to fire are factored. All storage tanks in tank-farm area are provided

with dykes. For each of the hazardous chemicals involved various scenarios such as pipe

line leaks of 5mm or pipeline ruptures or catastrophic vessel ruptures of the inventories



as outlined have been considered and damage distances for Lower Flammability Limits

(LFL) and heat radiation effects for the three levels of intensity are calculated and

presented in Table 6.14. Heat radiation damage distances for most of the scenarios are

not occurring. In case of pipeline leaks, 5 mm leaks are considered for 15 mm and 50 mm

pipe sizes. Very low release rates of material are obtained due to small leaks and cannot

create a major incident hazard. The concentration of the flammable material in the vapor

cloud was found to be below the lower flammability limits.



Table 6.14 Heat Radiation Damage Distances – Tank Farm S.No Name of Raw material Tank

Capacity (KL)

No.s Diameter (m)

Height (m)

Hole Dia

(mm)

Release Rate

(Kg/sec)

Heat radiation damage distances in m for KW/m2

37.5 12.5 4.0 1 Acetic Acid 23 1 1.5 4.2 25 0.33 <10 <10 <10 2 Toluene 12 2 0.8 2.8 25 0.40 <10 <10 11



6.7.2.13 Overpressure effects:

When an unignited gas cloud mixes with air and reaches the flammable range and if the

cloud ignites wither a flash fire or flash fire explosion can occur. Since the burning time is

shorter, instead of heat radiation from a flash fire, peak overpressure as a function of

distance from the centre of the cloud is derived. In case of pipeline leaks, damage

distances due to overpressure effects are not observed. The values are found to be similar

as there are no pressurized storage tanks in the tank farm, and the over pressure

distances are contingent on the tank capacity.

6.7.3 Observations:

From the previous incident records published in literature and hydrocarbon release data

bases, it has been observed that pinhole leaks contribute highest percentage where as the

second cause is small sized leaks of 25 mm diameter in tank farm, and 10 mm for drums.

6.7.4 Recommendations:

The following are the recommendations to minimize the hazards and improve the safety

of the proposed plants. Plants of this nature, which handle a variety of chemicals, face

problems of fire and vapor cloud explosions. It has been observed that for the proposed

plants the damage distances are more or less confined to the plant area only. Taking

precautionary safety measures as outlined below can further minimize these effects.

• In view of hazardous nature of operations, it is recommended to adopt best practices

with respect to design, operation and maintenance.

• It is recommended that all flammable areas and process area be maintained free of

ignition sources. Ensure that sources of ignition, such as pilot lights, electrical

ignition devices etc., at strategic locations like solvent storage areas are avoided.

• All electrical fittings involved in and around the pipeline and operation system

should conform to flame/explosion proof regulations.

• Strict hot work control and display of danger signs should be ensured.



• It is recommended to provide one fire hydrant point in the tank-farm area to take

care of any emergency. Installation of fire water hydrant net work is suggested.

• It is suggested to provide fire extinguishers in process plant at solvent storage area

and the vents of solvent tanks to be provided with PESO approved flame arrestors.

• Fire protection equipment should be well maintained so that it is available when

required. They should be located for quick accessibility. Provide carbon dioxide fire

extinguishers and DCP extinguishers for Electrical fires.

• It is suggested to have a periodical review of safety awareness and safety training

requirements of plant employees with respect to hazards present in the plant.

• In general, all pipelines carrying flammable liquids/vapor are periodically checked

for their integrity. Spillages have to be avoided and disposal should be done

quickly.

6.7.5 Transportation (Terms of Reference No. 7(iii))

Transportation of raw materials may result in accidents due to high speed collision, low

speed collision, overturning and non-accident-initiated release. The initiating and

contributing causes are presented in Table 6.15

Table 6.15 Truck Incidents – Initiating and Contributing Causes

Human Errors Equipment Failures System or Procedural Failures

External Events

Driver Impairment

Non-dedicated trailer Driver incentives Vandalism/ Sabotage

Speeding RR crossing guard Driver training Rain Driver Overtired Failure Carrier selection Fog Contamination Leaking Valve Container Specification Wing Overfilling Leaking Fitting Route selection Flood/washout Other Vehicle's Driver

Brake Failure Emergency response training

Fire at rest areas/parking areas

Taking Tight Insulation/Thermal Protection Failure

Speed Enforcement Earthquake

Unsecured Load Relief device failure Driver rest periods Existing accident Tire failure Maintenance Inspection Soft shoulder



Overpressure Time of day Restrictions

Material defect

Steering failure Sloshing High center of gravity Corrosion Bad Weld Excessive Grade Poor Intersection design Suspension system

The scenarios presented for storages are calculated for transport related

incidents/accidents and presented in Table 6.16.

Table 6.16 Transportation Specific Concerns

Concern Road Spill on Water Over or near a body of water Unconfined Pools In an undisturbed flat area BELVE-Induced catastrophic vessel failure

Possible if sufficient quantity in car with small leak to feed fire or if double tank trailer or burning fuel leak

Toxic products of combustion or reaction

Dependent on material and whether ignition occurs

6.8 DISASTER MANAGEMENT PLAN

6.8.1 INTRODUCTION

A disaster is a catastrophic situation in which suddenly, people are plunged into

helplessness and suffering and, as a result, need protection, clothing, shelter, medical and

social care and other necessities of life.

Disasters can be divided into two main groups. In the first, are disasters resulting from

natural phenomena like earthquakes, volcanic eruptions, storm surges, cyclones, tropical

storms, floods, avalanches, landslides, and forest fires. The second group includes

disastrous events occasioned by man, or by man's impact upon the environment.

Examples are armed conflict, industrial accidents, radiation accidents, factory fires,

explosions and escape of toxic gases or chemical substances, river pollution, mining or



other structural collapses, air, sea, rail and road transport accidents and can reach

catastrophic dimensions in terms of human loss.

There can be no set criteria for assessing the gravity of a disaster in the abstract since this

depends to a large extent on the physical, economic and social environment in which it

occurs. However, all disasters bring in their wake similar consequences that call for

immediate action, whether at the local, national or international level, for the rescue and

relief of the victims. This includes the search for the dead and injured, medical and social

care, removal of the debris, the provision of temporary shelter for the homeless, food,

clothing and medical supplies, and the rapid re- establishment of essential services.

An emergency may be said to begin when operator at the plant or in charge of storage of

hazardous chemicals cannot cope up with a potentially hazardous incident, which may

turn into an emergency. The emergencies could be a major fire or explosion or release of

toxic gas or a combination of them.

The proposed plant will store fuels, which are flammable in nature, and the storage will

be as per the Controller of Explosives and OISD norms. The hierarchy of the employees

is yet to be determined and the project is still in the initial stages of designing. Hence a

tentative disaster management plan is prepared to be suitably modified before

commissioning of the plant.

6.8.2 OBJECTIVES OF EMERGENCY MANAGEMENT PLAN (ON-SITE)

A quick and effective response during emergency can have tremendous significance on

whether the situation is controlled with little loss or it turns into a major emergency

Therefore, the objectives of this Onsite Emergency Plan (ONSEP);

During Emergency: Is to provide basic guidance to the personnel for effectively

combating such situations to minimize loss of life, damage to property and loss of

property.

• To localize the emergency and if possible eliminate it;



• To minimize the consequences of an emergency;

• To prevent spreading of the damage in other areas;

• To give necessary warning to plant personnel and neighborhood;

• To maximize resource utilization and combined efforts towards the emergency

operations;

• To mobilize internal resources and utilize them in the most effective way;

• To arrange rescue of persons, transport and treatment of causalities;

• To seek necessary help from industries in neighborhood or local authorities;

• To provide information to government agencies and to provide information to

public.

During Normal Time:

• To keep the required emergency equipment in stock at right places and ensure

their working condition;

• To keep the concerned personnel fully trained in the use of emergency equipment;

• Preserving records, evidence of situation for subsequent emergency etc.

6.8.3 SCOPE OF ONSEP

This ONSEP is prepared for industrial emergencies like fires, explosions, toxic releases,

asphyxia and does not cover natural calamities and societal disturbances related

emergencies (like strikes, bomb threats, civil Commissions etc). Also, the scope of this

ONSEP is limited to onsite emergencies and does not include measures for off site

Emergency Management. Necessary information with regards to Off Site Emergency

Management will be furnished to district authorities.

6.8.4 METHODOLOGY OF DEVELOPING ONSEP

The consideration in preparing this Emergency Plan includes the following steps:

• Identification and assessment of hazards and risks;

• Identifying, appointment of personnel & Assignment of Responsibilities;



• Identification and equipping Emergency Control Center;

• Identification of Assembly, Rescue points, Medical Facilities;

• Formulation of plan and of emergency sources;

• Training, Rehearsal & Evaluation;

• Action on Site.

Earlier, a detailed Hazard Analysis and Risk Assessment were carried out for the plant

facilities and the hazards are quantified. The likely locations of hazards and consequences

are evaluated, duly following the standard procedure.

6.8.5 ELEMENTS OF ONSITE EMERGENCY PLAN

Important elements considered in this plan are:

• Identification of emergencies

• Emergency organization

• Emergency facilities

• Emergency procedures

• Communications during emergency

• Rescue, Transport and Rehabilitation

• Roles and responsibilities of key personnel and essential employees

• Mutual aid.

6.8.5.1 Emergencies Identified

Spillage, pool fire, are the possible emergencies in the pipelines, fire near storage, DG

set, and Transformers are the other possible emergencies.

The other emergencies are asphyxiation of persons, apart from risks due to cyclonic

conditions, earth quake, lightning, floods (natural calamities), sabotage, bombing (social

and other reasons) etc. which are not under the management control.

Priority of protection in the event of an emergency is; Life and safety of personnel,

preservation of property, restoration of normalcy.



6.8.5.2 Emergency Organization

The project employs a total of 400 people in 3 shifts. The general shift will be for the

administrative employees, while the three shifts of 8 hours each are for technical

employees. Key personnel and essential employees are identified and are assigned

emergency responsibilities. The organogram of the essential organization are presented

below:

Security personnel, all operators, fitters, electricians etc. in the shifts are designated

essential employees. During emergencies, their services are drafted for essential

operations.

6.8.5.3 Emergency Facilities

a) Emergency Control Center (ECC)

It is a location where all key personnel like Chief Coordinator, Emergency controller,

maintenance coordinator can assemble and monitor aspects related to emergency and

take decisions related to emergency. The office room is designated as ECC. In case if this

area is affected, zone security room is designated as alternative ECC.

The following information and facilities would be maintained at the ECC in Plant Control

room:

Latest copy of Onsite Emergency Plan and Offsite Emergency Plan (as provided by

District Emergency Authority)

• Intercom Telephone;

• P& T Telephone;

• Telephone directories (internal and P&T);

• Factory Layout, site plan;

• P&I diagrams, electrical connections plans indicating locations of hazardous

inventories, sources of safety equipment, hydrant layout, location of pump house,

road plan, assembly points, vulnerable zones, escape routes;



• Hazard chart;

• Emergency shutdown procedures for generators and fuel supply system;

• Nominal roll of employees;

• List and addresses of key personnel;

• List and addresses of emergency coordinators;

• List and addresses of first aid providers;

• List and addresses of employees trained in fire fighting;

• List and addresses of qualified trained persons;

• Material safety data sheets of raw materials;

• Duties of key personnel;

• Important addresses and telephone numbers including those of fuel supplying

company, government agencies, neighboring industries and other sources of help,

outs side experts;

The following emergency equipment is made available at alternate ECC (Security point):

• Fire proximity suit/Gloves/Helmets;

• Hand tools suitable for pipe lines (non sparking type);

• Gaskets;

• Teflon tape;

• Gas Explosimeter;

• Flame proof torches/batteries;

• 1/2 crow bar;

• Spade;

• Manila rope;

• Spark arrestor;

• Spare fan belt for truck;

• First aid box;

• Special fire fighting information related to Hydrocarbon fuels;

• Public address megaphone, hand bell, Emergency torch.



b) Assembly points

Office room is identified as Assembly point and is in a low intensity fire affected zone.

Additionally the following places in plan are designated as safe assembly points: Time

office, and green belt area near the main road. The locations of assembly points would be

reviewed later.

c) Fire fighting Facilities

The fire fighting facilities which shall be provided are presented in Table 6.17.

Table 6.17 List of Fire Extinguishers S.No Description of Item Quantity

1. DCP 10 kg 6 Nos. 2. Foam 50 ltrs 3 Nos. 3. CO2 22.5 kg 3 Nos. 4. CO2 6.8 kg 8 Nos. 5. ABC Soda Acid 5 kg 3 Nos. 6. ABC Soda Acid 1 kg 9 Nos. 7. Fire Buckets with stand 15 Nos.

d) Location of First aid Boxes

The first aid boxes will be located at the following places: preparation areas,

administrative office, time office, and will be under the charge of security coordinator.

e) Emergency siren

Emergency siren will be provided with 0.5 km range of audibility and the location will be

time office. The siren will operate on regular supply and also on emergency electrical

supply. Shift electrical engineer of plant on receipt of information from shift incharge, is

authorized to operate the siren.

f) Emergency escapes

Emergency escapes in the plant area and floor wise emergency escapes will be

conspicuously marked.



g) Wind sock

Wind socks to observe the wind directions will be installed on the top of Turbine Plant

house.

6.8.5.4 Emergency Procedures

a) Procedure for Raising Emergency alarm

Whenever and whoever notices an emergency or a situation with a potential emergency

should forthwith raise alarm by calling on the available communication network or

shouting or approaching the shift in-charge, furnishing details. Anybody noticing fire

should inform the plant control room immediately. The shift electrical engineer at

control room informs the site controller.

b) Control Room staff

If an emergency is reported then plant control room staff must, request for the location,

nature and severity of emergency and obtain the caller's name, telephone number, and

inform the shift in-charge or site controller who ever are available in the shift.

c) Emergency communication

The following communications will be used during emergencies; P&T Telephones,

intercom, walkie-talkies, hand bell and siren. If any of the equipment is not working,

runners would be engaged to send the communication.

d) Warning/Alarm Communication of emergency

Emergency siren would be operated to alert all other employees on the orders of manager

(electrical). The emergency is communicated by the Emergency siren mode of wailing for

3 minutes. When the emergency has been brought under control, the Emergency

controller will direct plant control staff giving an 'all clear signal', by way of normal siren

(continuously for 3 minutes).



6.8.5.5 Rescue and Rehabilitation

Emergency vehicle will be made available round the clock under the charge of manager

(electrical) who is emergency coordinator. Security personnel are trained in rescue

operations. Persons rescued would be taken to First aid centre for further medical

attention or Safe Assembly Points as per the condition of the rescued person.

a) Transport Vehicles and Material Trucks

The transport vehicles and vehicles with materials would immediately withdraw to

outside the factory. Security guard of the shift is responsible for this. Transport vehicles

would wait at the security at the main entrance to provide emergency transport. This is

ensured by security coordinator.

b) Mock drill

Occasional mock drill is essential to evaluate that the ONSEP is meeting the objectives.

Adequate training is given to all staff members before conducting the mock drill. Mock

drills will be initiated with table top exercise, followed by pre-informed mock drills, and

few uninformed mock drills in the first phase. Functional exercises (communication,

Emergency shutdown, fire fighting at different locations, rescue etc.) are carried out in

the second phase.

Mock drills will familiarize the employees with the concept and procedures and help in

evaluating their performance. These scheduled and unscheduled mock drills are

conducted during shift change, public holidays, in night shift once in 6 months.

Response time, strict adherence to discharge of responsibilities, difficulties and

inconsistencies experienced are recorded and evaluated. Fire officer will assists

Emergency coordinator in designing and extending such mock drills and in evaluating

the response.



c) Review

The Emergency plan is reviewed periodically to evaluate the effectiveness, and during

change in organizational structure, isolation of equipment for longer duration, and

during increase in inventory of fuel and other chemicals. Manger Electrical and

Emergency coordinator initiates and authorizes such review as and when required, and

the changes if any will be duly informed to all the employees concerned.

6.8.5.6 Emergency Responsibilities

I. Site Controller

The chief coordinator shall be General manger and Alternate is Manager Electrical.

• He is overall in-charge of emergency operations.

• He reaches emergency control center as soon as he receives emergency

information.

• He coordinates with emergency controller, maintenance coordinator.

• He provides necessary resources required at the emergency site.

• He will inform the inspector of factories, and other statutory authorities.

• Prepares accident report/investigation.

• Arranges for keeping records of chronological events and orders an

investigation report and preserves evidence.

• Gives a public statement if necessary.

II. Emergency co-ordinator - EHS

On receiving the message about emergency;

• He will assume charge as chief coordinator till general manger arrives at

scene and takes charge as a chief coordinator.

• Takes actions to minimize the consequences and directs emergency

management and fire control/other causes with available personnel to put

off or to reduce the consequences.



• On the arrival of chief coordinator, he will hand over the charge of Chief

coordinator and assists him.

• He will identify the need of evacuating any personnel in the vicinity of the

affected zone.

• Exercises operational control of the installation and outside the affected area

and directs emergency operations.

• Declares emergency and orders plant control room for operation of

emergency siren.

• Continuously reviews and assesses possible development to determine

most probable courses of events.

• Initiates suspension of all work permits during the period of major

emergency for safe guarding the plant and other personnel.

III. Incident Controller

Block/Area In-charge assumes the role of incident controller in the following instances of

emergencies.

• Protects himself and proceeds to site quickly.

• Assess the magnitude of the incident.

• Initiates the emergency procedure to secure the safety of the workers and

minimise damage to installation and property.

• He will undertake all possible steps for safe isolation of plant systems, first

aid and fire fighting.

• He keeps in touch with plant control room till emergency controller arrives

at the scene of emergency,

• Organizes essential employees present in the shift.

• Ensures that adequate personal protective equipment is available foe

essential employees.

• Arranges for search of causalities.



• Arranges evacuation of non-essential workers to assemble at designated

assembly points.

• During the fire fighting operations seeks help from electrical/mechanical

maintenance personnel for isolation of machine/section involved in fire as

the need arises.

• Once the situation is under control, guides different persons for salvage and

cleanup operations.

• Assists in assessing the loss, preparation of accident report with the

assistance of security officer and senior officials of respective departments

present during the accident, investigates the fire with a view to find out

causative factors ad action needed to prevent recurrence.

IV. Engineering Service Division (ESD)

ESD In-Charge shall assume the role of maintenance coordinator. His

responsibilities include;

• Protecting himself.

• Reaching the emergency spot.

• Arranging all resources for assisting Emergency controller to mitigate the

Emergency scene, with respect to maintenance requirements.

• Assisting Emergency controller in arranging the needed containment

measures.

• Undertaking post emergency maintenance work upon termination of

emergency.

• Ensuring availability of adequate quantities of protective equipment and

other emergency materials, spare parts etc at Emergency control center.

• Ensuring upkeep of fire systems, emergency lighting in order.

V. Resource Coordinator – HR & Admin

Shift in charge shall assume the responsibility of resource coordinator.



• Arranges first aid, rescue acts, ambulance, attendance roster checking and

security.

• Interacts with chief coordinator for all emergency operations.

• Assists chief coordinator with necessary data and coordinates the

emergency activities.

• Maintains liaison with civil administration and mutual aid agencies -

neighboring industrial management.

• Ensures availability of humanitarian needs and maintenance of

rehabilitation center.

• Ensures emergency transport facility.

• Mobilizes extra medical help from outside if necessary.

• Maintains first aid and medical emergency requirements.

• Keeps list of qualified first aid providers and seeks their assistance.

• Ensures availability of necessary cash for rescue/rehabilitation and

emergency expenditure.

• Coordinates mutual aid.

• Participates in reviewing Emergency plan and arranges revision if required.

VI. Security In-Charge.

The production supervisor will assume the responsibilities of security coordinator, and

his responsibilities are;

• On receipt of fire call from plant control he prepares for fire fighting and

collects necessary equipment.

• Organizes rescue of persons trapped in work areas.

• Assists administration coordinator in organizing Mock drills, evaluation

and debriefing.

• During normal situations keeps the fire fighting capabilities in fully ready

condition by maintaining equipment.

• Organizes fire drills on periodic basis and evaluates the same.



• Arranges to clear off unconnected persons and trucks from the vicinity and

off the main gate.

• Instructs security guards posted on duty in the nearby industries to cordon

off the affected section and to control the crowd at the scene of fire.

• Arranges to control law and order till local authorities for Law and order till

police arrive at site.

• Post security guard at the scene of fire to check for possible re-ignition, after

the emergency is over.

• Assists Resource coordinator in organizing Mock Drills, evaluation and

debriefing.

VII. Person Noticing Fire

Any employee on noticing fire will take the following steps;

• Takes protection

• Raises alarm – shouts fire! Fire!! Fire!!! Or other emergency.

• Informs Shift In-charge, or at the control room over telephone giving clear

message about the exact location of fire and names of

equipment/machinery involved in fire.

• If Telephone is not working, quickly goes to either Plant Control Room and

informs.

VIII. Emergency Response Team (ERT)

The employees trained in fire fighting will take the following steps in the event of fire

apart from following the instructions of security coordinator apart from;

• Protects self

• Raises alarm

• Attempts to put out the fire using fire extinguishers.

• If necessary, operates fixed firefighting equipment.

• Stands by in safety for further instructions.



6.8.6 REMEDIAL ACTION

The cause of emergency is identified and action is taken from operation point of view

such as isolating or shutdown etc.

I. Failure of pipelines: feeding into the pipeline is stopped. Isolate the leaking

pipeline by closing the relevant valves. Transfer the material present to other

pipelines. Shutdown the pump. Close the suction and discharge valves of the

pump

II. Personal Protection: The people, who are assigned to the rescue operations,

must wear suitable personnel protective equipment such as self-contained

breathing apparatus and fire suit. They should remain in the incident area as

long as he can safely stay there. In spite of the wearing safety protective

equipment if he is unable to stay in the contaminated area, he should leave

immediately.

6.8.7 BASIC ACTION IN EMERGENCIES

Immediate action is the most important factor in emergency control because the first few

seconds count, as fires develop and spread very quickly unless prompt and efficient

action is taken.

• Take immediate steps to stop leakage/fire and raise alarm simultaneously.

• Initiate action as per fire organization plan or disaster management plan, based on

gravity of the emergency.

• Stop all operations and ensure closure and isolation valves.

• All effort must be made to contain leakage/fire.

• Saving of human life shall get priority in comparison to stocks/assets.

• Plant personnel with specific duties should assemble at the nominated place.

• All vehicles except those required for emergency use should be moved away from

the operating area, in an orderly manner by the predetermined route.



• Electrical system except for control supplies, utilities, lighting and fire fighting

system should be isolated.

• If the feed to the fire cannot be cut off, the fire must be controlled and not

extinguished.

• Start water spray system at areas involved or exposed to fire risks to avoid domino

effects.

• In case of leakage of chemicals without fire and inability to stop the flow, take all

precautions to avoid source of ignition.

• Block all roads in the adjacent area and enlist police support for the purpose if

warranted.

6.8.8 FIRE FIGHTING OPERATIONS

Enlist support of local fire brigade and neighboring industries.

• Fire fighting personnel working in or close to unignited vapor clouds or close to

fire must wear protective clothing and equipment including safety harness and

manned lifeline. They must be protected continuously by water sprays. Water

protection for fire fighters should never be shut off even though the flames appear

to have been extinguished until all personnel are safely out of the danger area.

• Exercise care to ensure that static charge is not generated in vapor cloud. For this

purpose solid jet of water must be avoided, instead fog nozzles must be used.

• Fire fighters should advance towards a fire in down wind direction.

• If the only valve that can be used to stop the leakage is surrounded by fire, it may

be possible to close it manually. The attempt should be directed by trained

persons only. The person attempting closure should be continuously protected by

means of water spraying (thorough fog nozzles), fire entry suit, water jet blanket

or any other approved equipment. The person must be equipped with a safety

harness and manned lifeline.



• Any rapid increase in pressure or noise level of should be treated as a warning of

over pressurization. In such case all personnel should be evacuated immediately.

• In case of any emergency situation, it is of paramount importance to avoid

endangering human life in the event of fire, involving or seriously exposing plant

equipment.



2. ENVIRONMENT MANAGEMENT PLAN







CONTENTS Page No.

1.0 Introduction 1‐11.1 Environment Management Plan 1‐2

1.1.1 Operation Phase 1‐2 2.0 Sources of Pollution from Manufacturing Process 1‐2 2.1 Water Pollution 1‐2

2.1.1 Process Description and Technical Specification of Effluent Treatment System 1‐4 2.2 Air Pollution 1‐8

2.2.1 Emissions from Utilities 1‐8 2.2.2 Emissions from Process 1‐9 2.2.3 Diffuse Emissions 1‐9 2.2.4 Fugitive Emissions 1‐9 2.2.5 Odor Management 1‐10 2.3 Solvent Use and Recycle 1‐10 2.4 Solid Waste 1‐11 2.5 Noise Pollution 1‐12 3.0 Rainwater Harvesting 1‐12 4.0 Occupational Safety and Health 1‐13 4.1 Medical Check ‐up 1‐14 5.0 Prevention, maintenance and operation of Environment Control System 1‐15 6.0 House Keeping 1‐16 7.0 Socio Economic Environment 1‐168.0 Transport systems 1‐16 9.0 Recovery – Reuse of Waste Products 1‐17 10.0 Energy Conservation 1‐17 11.0 Green Belt Development 1‐18 12.0 Corporate Environmental Responsibility 1‐2013.0 Environment Management Cell 1‐20 14.0 CREP Guidelines 1‐21 15.0 Other Management Practices 1‐21 16.0 Cost Estimate for Environment Management Plan 1‐22


List of Tables

List of Figures

S.No Description Page. No. 1.1 Total Effluents Generated and Mode of Treatment 1‐3 1.2 Effluents Generated and Characteristics from Process – Product Wise 1‐3 1.3 Technical Specifications of Effluent Treatment System 1‐6 1.4 Technical Specifications of Biological Treatment Plant 1‐7 1.5 Emission Details of Pollutants from Stack 1‐8 1.6 Total Solvent Balance – Product Wise 1‐10 1.7 Total Solid Waste and Mode of Disposal 1‐11 1.8 Frequency of Health Monitoring 1‐15 1.9 List of Plants Identified for Greenbelt Development 1‐18 1.10 Environmental Management Cost estimate 1‐22

S.No Description Page. No.1.1 Schematic Diagram of Effluent Treatment System 1‐5 1.2 Rain Water Harvesting Scheme 1‐12 1.3 Green Belt Development of M/s. Virchow Drugs Limited 1‐19

Virchow Drugs Limited Environment Management Plan


ENVIRONMENT MANAGEMENT PLAN

1.0 Introduction

Environmental protection is an issue that no organization can neglect and hope to survive.

The by-products of civilization are being dumped upon the environment to a degree that the

environment finds difficult to assimilate. The key to the success of the integrated approach to

pollution prevention and control is the management and operation of the organization.

Effective committed management delivers a successful industry. As total commitment to the

environment, not just for compliance with legal or regulatory compliance will be the essence

of environment management of an industry. Many companies have recognized the benefits

of implementing an effective environmental management system.

Environmental management plan can be effectively implemented to mitigate the pollution

levels by observing the following;

1. Pollution will be prevented or reduced at the source,

2. Pollution that cannot be prevented will be recycled in an environmentally safe manner,

3. Pollution that cannot be prevented or recycled will be treated in environmentally safe

manner, and

4. Disposal and other releases into the environment will be used “only as a last resort”

and will be conducted in an environmentally safe manner.

The management plan is drawn in consultation with the project proponents with reference to

various potential monitored, identified and predicted in the previous chapters. And the

necessary measures to be taken for the mitigation and control of the same presented, various

pollution control measures adopted which are present in the proposed expansion and

measures identified for adoption are discussed in the Environmental Impact Assessment

Report of the same are presented in appendix of the Environmental Impact Assessment

Report. Review of the process is the essential component of Environmental Management M/s.

Virchow Drugs Limited has been conducting experiments to optimize the consumption of

raw materials and to increase the purity of the product.



1.1 Environment Management Plan

1.1.1 Operation Phase

During operation stage the major pollution from the proposed expansion is from liquid

effluents from process, utilities and domestic facilities, and air pollution from utilities and or

combustion of fuels/wastes. The effluent treatment system based on zero liquid discharge

principle, shall convert most of the liquid effluents to solids by way of evaporation of salts

and ETP sludge. The environment management plan is drawn in consultation with the project

authorities, R&D experts of Granules Limited and other technical consultants involved in

preparing the project plan. The management, mitigation and enhancement measures

identified for significant impact sources are presented as follows;

2.0 Sources of Pollution from Manufacturing Process:

The major contributions of pollution from proposed project are effluent generation from

process, utilities and domestic sources and gaseous emission from process and utilities. The

water pollution is due to the effluent generated from process, washings, Scrubber, utility

blow downs and domestic sources. Majority of effluents generated will be from process and

it will have considerable amount of COD and TDS load and suspended solids, which has to

be effectively treated. The air pollution is caused due to combustion of both fuels and

solid/gaseous wastes. The quantities and quality of effluents, emissions and solid wastes

are identified and quantified in the environmental impact assessment study. The

environment management measures proposed are described as follows;

2.1 Water Pollution (Terms of Reference No. 3 (vi) & 7(iv))

The effluents generated in the process, separation techniques and during purification

contain organic residues and inorganic raw materials, solvents, and products. Hence the

effluents contain both organic and inorganic salts in various quantities leading to high COD

and TDS levels respectively. Effluents from process, washings, Scrubbing media, utility

blow downs and domestic effluent will be sent to the effluent treatment system. The treated

effluent will be reused for cooling tower makeup. The total effluent generated and mode of



treatment is presented in Table 1.1. The quantity and quality of effluents generated from

process for each product is presented in Table 1.2.

Table 1.1 Total Effluents Generated and Mode of Treatment

Description Quantity (KLD) Mode of Treatment Permitted After

Expansion HTDS Effluents (TDS & COD> 15000 mg/l)

Process 9.045 51.97 Sent to Stripper followed by forced evaporator and ATFD. Stripper Condensate is reused in process. Evaporator and ATFD Condensate sent to Biological treatment plant followed by RO. RO rejects sent to Forced evaporator and permeate are reused in cooling towers make-up.

Scrubber Effluent 3 Sent to Forced evaporator followed by ATFD, Biological treatment plant and RO.

RO/DM rejects

4.5




Table 1.2 Effluents Generated and Characteristics from Process – Product Wise S.No Name of Product Quantity (Kg/Day) Conc. (mg/l)

Water Input

TDS COD Total Effluent

TDS COD

Group - I 1 Sulfanilamide 42000 8171 730 51969.4 157236 14053

Group - II 2 Sulfarpyridine 22000 4351 2040 28624.5 152002 71272 3 Sulfa salazine 20000 2078 839 20479.5 101491 40946 Total - II 42000 6429 2879 49104.0 130935 58624

Worst Case - Any One Group 42000 8171 2879 51969 157236 55392



2.1.1 Process Description and Technical Specification of Effluent Treatment System


effluents are segregated into two streams; High COD/ TDS and Low COD/ TDS streams.

The effluents are segregated stream wise based on the characteristics of effluents, i.e., less

than 15000 mg/l of TDS and COD are considered as low TDS effluents, while the others are

considered as high COD/TDS effluents.



Neutralization, Settling tank, Stripper, forced evaporator followed by Agitated Thin Film

Dryer (ATFD). The organic distillate from the stripper is reused in process and aqueous

bottom from stripper is sent to forced evaporator followed by ATFD for evaporation. The

condensate from the forced evaporator and ATFD are sent to ETP (Biological). Salts from

ATFD are disposed to TSDF.


These effluents along with the condensate from forced evaporator and ATFD are treated in

primary treatment consisting of equalization, neutralization, and primary sedimentation

followed by secondary biological treatment consisting of aeration tank and clarifier.

The treated effluents after biological treatment are subjected to tertiary treatment in a reverse

osmosis system. Permeate from RO is reused for cooling tower and rejects are sent to forced

evaporator followed by ATFD. Sludge from various units of Biological treatment are

thickened in sludge handling system and sent to TSDF. Schematic diagram of effluent

treatment system is presented in Fig 1.1. Technical specifications of effluent treatment system

is presented in Table 1.3 and 1.4 respectively.



Fig

1.1

Sche

mat

ic D

iagr

am o

f Eff

luen

t Tre

atm

ent S

yste

m

Strip

per

Multip

le Effec

t Ev

apor

ator

Agita

ted Th

in

Film Dryer

Salts to TSD

F

Settlin

g tank

Equa

lization

& Ne

utraliz

ation

Org. Dist

illate

reus

ed in Pro

cess

Orga

nic

Distilla

te

High TD

S/CO

D

CondensateLo

w TDS &

COD

Scre

enCh

ambe

r

Slud

ge

Dryin

g Be

d

Oil

Skim

mer

Equa

lization

& Ne

utraliz

ation

Aeratio

nTa

nkClarifier

Holding

Tank

Filte

rs

Trea

ted W

ater

Stor

age Ta

nk

Filte

r Pre

ss

Slud

ge Cak

e to

TSDF

Doub

le

RO Pl

ant

Recy

cle W

ater

Colle

ction

Sump

To C

oolin

g To

wer

s

Rejects

Scru

bber Effluen

t, DM

/RO

Rejects

To M

EE

Slud

ge to

TSDF



Table 1.3 Technical Specifications of Effluent Treatment System S.No Description Unit Capacity

Existing Proposed Stripper for Process and Washings

1 Design Capacity KLD 56 2 Feed Rate Kg/hr 2166 3 Specific Gravity of Feed ≈ 1.2 4 Initial Feed COD PPM 55392 5 Feed Total Solid % 18.8 6 High Heating Temperature OC 80 7 High COD Condensate recovery LPH 90 8 Dry Saturated Steam requirement at 3.0Kg/cm2 (g) TPH 0.3 9 Cooling Water circulation rate for condenser m3/hr 10 10 Cooling Water Inlet Temperature OC 30 11 Cooling Water Outlet Temperature OC 33 12 Operating Condition

Forced Evaporator 1 Design Capacity KLD 15 45 2 Feed Rate Kg/hr 500 1576 3 Feed Concentration mg/l 150000 157236 4 Feed Temperature OC 80 5 Initial Solids % 20 18.8 6 Solids in Concentrate % 30 30 7 Concentrate Output Kg/hr 330 1030 8 Water Evaporation Rate Kg/hr 170 546 9 Designed Water Evaporation Rate Kg/hr 250 750 10 Dry Saturated Steam requirement at 5.0Kg/cm2 (g) TPH 0.2 0.6 11 Cooling Water Circulation Rate at 30 – 32OC m3/hr 40 120 12 Cooling Water Inlet Temperature OC 30 30 13 Cooling Water Outlet Temperature OC 33 33

Agitated Thin Film Dryer (ATFD) 1 Designed Capacity KLD 20 20 2 Designed Heat Transfer Area Sq.m 25 25 3 Feed Rate Kg/hr 680 680 4 Initial Feed Solid Content % 30 30 5 Final Moisture in Dry Bag-gable Product % 8 8 6 Water Evaporation Rate Kg/hr 450 450 7 Designed Water Evaporation Kg/hr 750 750 8 Solid Output in Bag-gable form at 5 – 10% moisture Kg/hr 230 230 9 Dry Saturated Steam requirement at 5.0Kg/cm2 (g) TPH 0.5 0.5 10 Cooling Water Circulation Rate at 30 – 32OC m3/hr 130 130 11 Cooling Water Inlet Temperature OC 30 30 12 Cooling Water Outlet Temperature OC 33 33



Table 1.4 Technical Specifications of Biological Treatment Plant Design inputs Data Flow from Evaporation : 42.0 KLD LTDS effluent : 50.0 KLD Total Flow : 92 KLD Design Capacity : 96 m3/day 1.Equalization Tank Peak Flow ( Designed) : 3.83 m3/hr Hydraulic retention time : 10 Hrs. at peak flow Volume of the tank : 40 m3 Tank dimensions : 4 x 4 x 2.5 L X B X H, m Air required for agitation : 0.01 m3/m2 min Total air required : 9.6 m3/hr Air blower required : 3HP m3/[email protected] 2) Primary clarifier Design quantity : 92 KLD Width : 2300 mm Length : 1300 mm Depth : 1200 mm No.of plates : 15 3) Biozone (Aeration)Tank Actual Flow : 92 KLD Length : 6900 mm Width : 2200 mm Diameter of Rotor : 1500 mm No of Rotors : 3 No.s 4) Secondary Clarifier : Width : 2300 mm Length : 1600 mm Depth : 1200 mm No.of plates : 22 5). Holding tank The flow from the each individual settling tank I,e the supernatant liquid is let into the respective Pre-Filtration Tank, which has a minimum 8 hours holding capacity. 6) MGF Capacity : 92 KLD Feed pump flow rate : 4.0 m3 Head : 30 m 8. ACF Capacity : 92 KLD Feed pump flow rate : 4.0 m3 Head : 30 M Rverse Osmosis Plant – I : 70 KL Rverse Osmosis Plant – I : 20 KL



2.2 Air Pollution (Terms of Reference No. 3 (vi))



equipment etc. Purification would be conducted in reactors or filtration equipment. The

transfer of materials will be through closed pipelines. Various sources of emissions are

identified from process operations. The usage of boiler for steam generation and DG sets

for emergency power back up also releases emissions.

2.2.1 Emissions from Utilities (Terms of Reference No. 7(v))

It is proposed to establish 4 TPH coal fired boiler for proposed expansion and changing fuel

of existing 3TPH boiler from Oil fired to Coal fired and dismantling existing 1 TPH coal

fired boiler after expansion. The proposed air pollution control equipment for boiler is

Multicone Cyclone separators. DG sets shall be provided with stack heights based on the

CPCB formula for effective stack height. The emission rates of SO2, NOx and SPM from

each stack are presented in Table 1.5.

Table 1.5 Emission Details of Pollutants from Stack S.No Stack Attached to Stack

Height (m)

Dia of stack

at top (m)

Temp. of exhaust

gases (0C)



PM SO2 NOx

Existing 1* 1TPH Oil fired

boiler 30 0.4 130 8 0.03 0.12 0.02

2** 3 TPH Coal Fired Boiler

30 0.6 160 12 0.15 0.4 0.21

3# 200KVA DG Set 3 0.1 200 10 0.003 0.08 0.01 4# 500 KVA DG set 7.5 0.2 160 15 0.004 0.16 0.03


Boiler 30 0.8 160 8.5 0.2 0.4 0.5

* Shall be dismantled after expansion ** Fuel changed from oil to coal. # DG sets will be used during load shut down by TSTRANSCO.



2.2.2 Emissions from Process

The source of process emissions are reactors, where gaseous products are released, or excess

gaseous raw material used in production, which mainly contain inorganic gases. The other

emissions from process operations and effluent treatment system are mainly known as

diffuse emissions containing dusts, fumes and volatile organic compounds. The VOCs from

among the diffuse emissions are the main cause of odour in the plant area and its

neighborhood. Spillage, leakage and accidental releases are the causes of fugitive emissions,

releasing solids, liquids and fumes of volatile organic compounds resulting in soil and

ground water contamination in addition to odour in the plant area.

2.2.3 Diffuse Emissions

Emissions are also released from various operations of manufacturing like centrifuge,

drying, distillation, extraction etc. These emissions mainly contain volatile contents of the

material sent for processing. The emissions are normally passed through vent scrubber

before releasing into atmosphere to mitigate odour. The emissions from distillation are

passed through condensers, which mitigate odour. It is proposed to provide vent

condensers in series to reactors, distillation columns, driers and centrifuge etc. to mitigate

VOC emissions release. Other vents are connected to common headers and scrubbers. The

transfer of solvents shall be mainly by closed pipeline systems, while drum transfer is by

using air operated diaphragm pumps in closed hoods. The charging of solid raw materials

shall be by using closed hoppers to avoid dust emissions and hazard of static electricity.

Breather valves shall be provided to storage tanks. Thermal insulation and condensers will

be provided for storage tanks of low boiling point solvents. The reactor or solvent storage

tank vents when not use shall be kept closed.

2.2.4 Fugitive Emissions


periodic maintenance program shall ensure integrity of equipment mitigating the


management scheme as mentioned in the respective MSDS, spill control kit shall be



provided in storage, and production blocks. The fugitive emissions shall be reduced by

closed transfer and handling of all hazardous solvents and chemicals. The ventilation

system provided will reduce health impact on the employees by way of dilution of work

room air and also dispersion of contaminated air.

2.2.5 Odour Management ((Terms of Reference No. B(6))

Odour is caused mainly by diffuse and fugitive emissions of low boiling organic chemicals/

compounds releasing volatile organic compounds. The above mentioned measures for

mitigation and control of diffuse and fugitive emissions shall reduce release of VOC’s into

atmosphere and the resultant odour.

2.3 Solvent Use and Recycle

Solvents are used for extraction of products and as reaction medium. Solvents constitute

major consumable material of synthetic organic chemical manufacturing, mainly used as

reaction medium. The used solvents constitute major waste stream of synthetic organic

chemical manufacturing. Hence it is proposed to recycle the solvents by distillation for reuse

in process, thereby reducing total solvent consumption in the plant and reducing the waste

quantity to be disposed. The distillation columns are mainly provided to remove moisture

and impurities from spent single solvents, and mixed solvents. The recycled single solvents

are reused in the process, while the mixed solvents are sold to end users. The total solvent

balance product wise and stage wise is presented in Table 1.6.

Table 1.6 Total Solvent Balance Name of Product Name of Solvent Quantity (Kg/day)

Solvent Used

Recovered Fugitive Loss

To wastewater

Sulfapyridine Toluene 8900 8633 80.1 186.9 Pyridine 5350 5189.5 48.2 112.4

Sulfa salazine Acetic Acid 1710 1624.5 13.7 71.8



2.4 Solid Waste (Terms of Reference No. 3 (vi) & 7(vii))

Solid wastes are generated from the process, solvent distillation, wastewater treatment and

utilities. The effluent treatment system generates, stripper distillate, ATFD salts and ETP

sludge. The process operations generate process residue, activated carbon and inorganic

residue. The utilities i.e., coal fired boiler generates ash while DG sets generate waste oil and

used batteries. All the wastes except coal ash are considered hazardous. The other non

hazardous wastes are container, packing material, empty drums etc. The containers and

drums are detoxified before disposing to authorized buyers. The hazardous wastes of

process residue and activated carbon are sent cement plants for co-incineration, thereby

reducing the load on TSDF facility and consumption of non renewable resource of coal in

cement plant kilns, stripper distillate is reused in process. The inorganic wastes, salts from

ATFD, and ETP sludge are sent to TSDF facility located at Dundigal, Ranga Reddy district.

The waste oil and used batteries are sold to authorized recyclers. Coal ash is sold to brick

manufacturers in the local area. The quantity and disposal plan for the solid wastes is


Table 1.7 Solid Waste and Mode of Disposal S.

No Description Units Quantity Mode of Treatment/Disposal


1 Ash from Boiler TPD 5.44 18.74 Sold to Brick manufactures and cement plants

2 Organic residue TPD 0.86 Sent to TDSF/Cement Plants for Co-incineration

3 Stripper Distillate KLD 2 Reused in process 4 Spent Carbon Kg/day 53 140 Sent to Cement Industries for

Co-incineration. 5 Inorganic Residue TPD 0.582 Sent to TSDF 6 Evaporation salts TPD 1.145 9.77 Sent to TSDF 7 ETP Sludge Kg/

month 280 Sent to TSDF

8 Detoxified containers

No.s/ Month

10 300 Sold to authorized vendors

9 Waste oil Lit/ Month

5 15 Sent to Authorized Recyclers

10 Used batteries No.s/Yr 10 15 Sent to Authorized Recyclers



2.5 Noise Pollution

Noise is anticipated from motors, compressors and DG set. The DG shall be kept in a

separate enclosed room with acoustic enclosure. The motors and compressors shall be

provided with guards and shall be mounted adequately to ensure the reduction of noise and

vibration. The employees working in noise generating areas shall be provided with

earmuffs.

3.0 Rainwater Harvesting (Terms of Reference No. 7(x))

Rain water harvesting shall be adopted by providing rain water harvesting structures along

the drains, storm water storage sump and tanks. Storm water drains are provided with rain

water harvesting structures which will act as flow dissipaters and also as infiltration

trenches. Filtration points shall ensure percolation of water and enhance the ground water

table. The site area will be provided with 10 nos. of rain water harvesting structures. The

roof water shall be collected in a sump of 25 KL capacity connected to down spouts of the

roofs, and the collected water shall be reused for process and green belt development. The

The scheme for rain water harvesting structure is presented in Fig 1.4.

Fig 1.2 Rain Water Harvesting Scheme



4.0 Occupational Safety and Health (Terms of Reference No. 8(iii) & B(14))

Many worker health and safety hazards are posed by synthesis operations. They include

safety hazards from moving machine parts, pressurized equipment and pipes; heavy manual

handling of materials and equipment; steam, hot liquids, heated surfaces and hot workplace

environments; confined spaces and hazardous energy sources (e.g., electricity); and high

noise levels.

Acute and chronic health risks may result from worker exposures to hazardous chemicals

during synthesis operations. Chemicals with acute health effects can damage the eyes and

skin, be corrosive or irritating to body tissues, cause sensitization or allergic reactions or

be asphyxiants, causing suffocation or oxygen deficiency. Chemicals with chronic health

effects may cause cancer, or damage the liver, kidneys or lungs or affect the nervous,

endocrine, reproductive or other organ systems. Worker exposure to chemicals can occur

during manufacturing when chemicals spill, leak, or discharge from the process system and

contaminate areas where workers are present. The most frequently reported industrial

exposure occurs during the transfer of materials. The entry of workers into systems,

equipment, or enclosures that are contaminated may occur inadvertently, but routine

servicing, nonscheduled maintenance, and process monitoring appear to be the kind of

activities with potential for significant exposure. Health and safety hazards may be

controlled by implementing appropriate control measures (e.g., process modifications,

engineering controls, administrative practices, personal and respiratory protective

equipment).

The process modification shall be a constant exercise of the Research and development wing

of the organization, resulting in reduced pollution loads, and increased yields. The measures

proposed are selection of alternative solvents/routes of synthesis, avoidance of hazardous

chemicals usage, and application of green chemistry principles.

The engineering controls proposed for reducing occupational hazards are; provision of

scrubbers, condenser systems for process equipment, piping systems, insulation to reactors,



usage of transfer pumps with mechanical seals, AOD pumps, trolleys for transfer of drums

or bags, closed hoods for charging raw materials, dip pipe provision for solvent and liquid

raw material charging, level indicators, pressure and temperature indicators, barrier guards

on moving machine parts, optimization of chemical inventory, control switches and

emergency stop devices to mitigate and avoid physical, chemical, electrical and mechanical

hazards.

Administrative practices proposed for improving occupational safety are induction training

programs, safety training programs, rotation of workers, implementation of proactive

maintenance schedule, provision of standard operating procedures for all plant operations,

access to MSDS for all employees, access to emergency numbers of contact, and avoidance of

crowded work place, and provision of occupational safety centre.

Personal protective equipment shall be provided to all the employees including contract

employees. All the employees shall be provided with gumshoe, helmet, masks, goggles. The

other equipment like ear muffs, gloves, respirators, aprons etc., will be provided to

employees depending on the work area allocated to them. The PPE selection shall strictly

follow the prescribed guidelines of MSDS.

4.1 Medical Check-up (Terms of Reference No. 8(ii))

The plant have a medical program of pre employment screening, periodic medical

examination, emergency treatment, non emergency treatment, and record keeping and

review. The pre employment screening and periodic medical examination shall follow the

guidelines of factories act. The pre employment screening shall obtain medical history,

occupational history followed by physical examination and baseline monitoring for specific

exposures. The frequency of periodic medical examination and type of evaluation is




Table 1.8 Frequency of Health Monitoring

Occupation Type of evaluation Frequency Process area Chest X-ray, spirometry and vision testing,

complete blood count, platelet count, and measurement of kidney and liver function, and medical examination with focus on liver, kidney, nervous system and skin,

Every 5 years to age <30; every 4 years to age 31 – 40; and every 2 years to age 41-50; Once a year above 50 years.

Noise prone areas

Audiometry Annually

The plant shall have an occupational health centre to provide emergency and non emergency

treatment, by way of emergency first aid on site, liaison with local hospitals and specialists,

arranging decontamination of victims, arranging transport of victims to hospitals, and to

transfer medical records, and to provide details of incident and medical history to next care

provider. The occupational health centre shall be supervised by a qualified physician. The

occupational health centre shall maintain the health records and shall analyse the records for

any common symptoms and common health problems which may be due to exposure to

chemicals, and or due to other occupational hazards.

5.0 Prevention, maintenance and operation of Environment Control System

The pollution control equipment, and the effluent treatment systems and effluents will be

monitored periodically and will be checked for its performance and pro-active maintenance

will be adopted. The environmental monitoring results will be evaluated to identify the

problems/under performance of the equipment. Necessary steps will be taken to rectify the

identified problems/defects. The management agrees that the evaluation of the performance

of pollution control measures and occupational safety measures to arrive at their efficiency

and proposes to adopt new measures for efficient pollution control which will be a regular

exercise.

All pollution control equipments are adequately designed and operating staff of the

pollution control equipment have good experience in the operation and maintenance of the

equipment. Standby equipment provided for all critical equipment to ensure continuous

operation of pollution control equipment and preventive maintenance is done as per the



schedule to avoid breakdown. Characteristics of influent and effluent are monitored on daily

basis by the industry and air emissions and effluent characteristics on monthly basis by third

party.

6.0 House Keeping

Good house-keeping practices will be adopted. Floor washing is avoided and wet mopping

will be adopted to minimize liquid waste generation. Paper waste is minimized by adopting

intra office network. Sufficient workspace and proper lighting will be provided.

7.0 Socio Economic Environment (Terms of Reference No. 11(i)

The expansion of project provides an opportunity for the local people to get employment

directly or indirectly and helps in the up liftment of the socioeconomic status of the area. The

project proponents propose to involve in social activities of the stakeholders/surrounding

community by planning the betterment of neighbouring social conditions through awareness

and welfare programs will ensure an improved relation, useful in the long run. Many of the

beneficiaries of such programs shall include own employees as well. The goodwill of the

local populace can never be ignored. Another important facet of social environment

identified by the project proponents is a green appearance, hence the management will

develop a green belt towards aesthetic beautification as the same is necessary to be

considered as a responsible, social neighbour.

1. Social Investment Funding: 2% of the profits of the unit are spent on socio

economic development programs in consultation with revenue authorities and

public representative annually. 2.5% of the capital cost i.e., Rs. 5 lakhs shall be

spent additionally during 2016-2021. The investment on CSR activity shall benefit

the stake holders within the impact area.

2. Local Content: 25% employees are from the surrounding villages.

8.0 Transport systems

All the raw materials and finished products are transported by road. Dedicated parking

facility is provided for transport vehicles. The plant is located in an industrial area, and



there will not be any unauthorized shop or settlements along the road connecting the plant

site. There will be 2 truck trips per day to the factory. Traffic signs are placed in the battery

limit. The drivers of the vehicles will be provided with TREM cards and will be explained the

measure to be adopted during various emergencies.

9.0 Reduce, Recovery and Reuse (Terms of Reference No. 7(vii))

It is the endeavor of the project authorities to increase the yields of the products through

constant research and development activity. The development activity shall concentrate on

increasing the yields, using less quantity of raw material, using alternative solvents with low

hazards adopting green chemistry principles. The solvents shall be recycled for reuse in the

process by distillation. The mother liquors from the first crop shall be reused for process.

The cleaning cycles will be reduced by adopting appropriate production plan with minimum

changeovers of the product. Hydro jets or high pressure cleaning shall be adopted for

washing the reactors to minimize washing effluents. It is proposed to use third and fourth

washing water for first and second washing of the reactor and centrifuges. The steam

condensate shall be reused for boiler feed. Treated effluent is reused for cooling tower

makeup, while boiler blow down is reused for scrubbing. A cross functional team shall

constantly evaluate various options of reduce, reuse and recycle for water conservation,

reduction in wastewater generation, effluent segregation, reuse of wastes, alternate treatment

methods, leakage/spillage control, avoidance of overflow and contamination. As part of the

above exercise the proponent identified few compounds which can be recovered as

byproducts and sold. It is also proposed to explore recovery of various salts from MEE salts,

and from process effluents to reduce effluent loads, and quantity of solid waste.

10.0 Energy Conservation (Terms of Reference No. 7(vii))

It is proposed to use screw compressors (Air/Refrigeration) for energy efficiency ( 10 – 12%

saving), evaporative condensers in the chilling circuit to reduce overall power, Cooling tower

fan control to switch off at times not required (Low temp), energy efficient pumps to conserve

energy.



11.0 Green Belt Development (Terms of Reference No. 7(ix))

The Granules India Limited is an existing chemical plant. Green belt is developed in an

area of 0.99 acres, covering the boundary of the site as part of environment management

plan. It has taken adequate measures for prevention and control of pollution. It has a

fully fledged Environment monitoring management cell. As there is no provision for

expansion of greenbelt on three sides of this old plant, it is proposed to grow more

numbers of trees in the lands owned by the industry in its close proximity. A list of

plants identified for reinforcement of greenbelt and avenue plantations is given in Table

1.9 and green belt plan presented in Fig. 1.3

Table 1.9 List of Plants identified for Green belt Development Botanical name Importance Acacia auriculiformis Tall Evergreen drought resistant Avenue tree Ailanthus excelsa Tall branched semievergreen tree. Albizia lebbeck Branced evergreen leguminous tree Alstonia scholaris Beautiful medicinal tree. Azadirachta indica Neem oil & neem products Bauhinia racemosa Ornamental tree Cassia fistula Ornamental and bark is a source of tannin Cassia siamea Ornamental avenue tree Cocos nucifera Coconut palm Dalbergia sissoo Avenue and timber tree Dendrocalamus strictus Bamboo products Casuarina equisetifolia Pulp and construction material Delonix regia Ornamental avenue tree Eucalyptus sp Grown in high density along the boundary Ficus benghalensis Shade and a source of food for birds Ficus racemosa Edible fruits Ficus religiosa Shade and a source of food for birds Gmelina arborea Timber Muntingia calabura Shade and edible fruit Polyalthia longifolia Avenue tree Samania saman Shade, timber and fruits are a good live stock feed. Sapindus emarginatus Soap nut tree Spathodea companulata Ornamental avenue tree Terminalia arjuna Common avenue tree Terminalia catappa Yield edible almond seed Syzygium cumini Edible fruits Tamarindus indica Tamarind fruit and leaf Tectona grandis Timber



Fig 1.3 Green Belt Development of Virchow Drugs Limited



12.0 Corporate Environmental Responsibility (Terms of Reference No. 9(i))

The broad guidelines of the Environmental Policy are presented below. The environmental

Management System shall have standard operating procedures for various aspects identified

which include infringement/deviation/violation of Environmental related statutory

regulations.

Broad guidelines of the Environmental Policy

Virchow Drugs Limited is committed to take adequate precautions related to Environment,

Health and Safety in developing manufacturing, storing and handling of chemical products

and in its business. It is our policy to provide a workplace free from accidents, injuries and

exposure to hazardous chemicals; conserve natural resources and prevent pollution to protect

the environment.

Towards this, we have set our objectives and are committed to:

Comply with applicable Environment, Health and Safety (EHS) legislation and statutory, regulatory and other requirements

Respond to community concerns regarding EHS and address them proactively in our operations

Integrate EHS considerations into Business Planning and decision making Use process safety management techniques like Safety Audits, Analysis, Operability

Studies and Documentation of safety related information to minimize EHS associated with our operations

Euip ourselves to address EHS emergencies Champion EHS responsibility among all the employees and impart the requisite

training Communicate our EHS policy and other concerns to our contractors and vendors and

seek their compliance Continually review objectives and set targets to improve our EHS performance

13.0 Environment Management Cell (Terms of Reference No. 9(iii))

The post project monitoring can be an activity of M/s. Virchow Drugs Limited is by hiring

services of the consultants. The industry shall have environmental wing which is supervised

by the production manager and the following staff is available under this wing:

Production Manager : 1 no.



Operator :4 nos. Chemists : 3 nos. Fitters : 3 nos.

Records shall be maintained for the analysis of raw effluents and treated effluents, ambient

air quality data, stack emissions monitoring results, micrometeorological data and noise

levels. These records are not only required for the perusal of the pollution control board

authorities but also to derive at the efficiencies of the pollution control equipment as the

objective of the project proponent is not only compliance with statutory regulations, but also

a serious commitment towards clean environment.

The industry shall be regularly maintaining the records as per the hazardous waste

regulations and EPA regulations and is applying for the annual consents for air and water,

and renewal of authorization for the storage of hazardous waste.

14.0 CREP Guideline and Compliance (Terms of Reference No. 47) CREP Guideline Compliance

Segregation of waste streams Segregation of waste streams at source Detoxification and treatment of high COD waste streams

High COD waste streams are neutralized and detoxified as present practice

Management of solid waste Hazardous waste is sent to CHWTSDF. Minimum scale of production to afford cost of pollution control

Production capacities optimized.

Long term strategies for reduction in waste Reduction of waste generation by increasing the yields is a major R&D activity.

Control of air pollution Scrubbers provided to all vents and air emission of reactions apart from multi cone cyclone separators to boiler.

Self – regulation by industry though regular monitoring and environmental auditing

Third party monitoring conducted quarterly

Optimizing the inventory of hazardous chemicals

Storage of chemicals optimized for one week.

15.0 Other Management Practices

The industry will maintain records as per the hazardous waste regulations and EPA

regulations and apply for the annual consents for air and water, and renewal of

authorization for the storage of hazardous waste as per Hazardous Waste (Handling &



Management) Rules, 1989 and subsequent amendments. The records of hazardous waste

manifest will be maintained.

The industry shall obtain the consent for operation (CFO) as required under section 25/26 of

the Water Act, 1974 and under section 21/22 of Air Act, 1981 before trial production and

commissioning from the Sate Pollution Control Board. The CFO will be renewed each year

by the industry. The industry will obtain the necessary permissions under Hazardous Waste

(Management and Handling) Rules 1989, and Manufacture, Storage and Import of

Hazardous Chemicals Rules, 1989, issued by the Ministry of Environment and Forests, New

Delhi. The industry will submit environmental statement every year before September 30,

and monthly water cess returns. The management ensures that it will comply with all the

directions and regulations issued by the Ministry of Environment and Forests, New Delhi,

State and Central Pollution Control Boards. The Consent for Establishment, Consent for

Operation will be displayed in a conspicuous location for the information of the inspecting

authorities of different departments.

16.0 Cost Estimate for Environment Management Plan (Terms of Reference No. 7(xi)

It is estimated that the total capital cost for implementing the Environment Management

plan is Rs. 167.8 Lakhs, while the recurring costs for the same is Rs. 134.2 Lakhs/year. The

cost estimate is presented in Table 1.10.

Table 1.10 Environmental Management Cost estimate S.No Description Recurring Cost-

Annum Capital Cost

1 Air pollution Control 6 20 2 Water pollution Control 70 100 3 Noise pollution Control 0.2 0.8 4 Environment Monitoring and Management 3 6 5 Occupational Health 3 8 6 Green Belt 2 3 7 Others (S. Waste) 50 30

Total (Lakhs) 134.2 167.8 Note: Value in Rs. Lakhs



3. COMPLIANCE OF TERMS OF REFERENCE






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

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

A. STANDARD TERMS OF REFERENCE1) Executive Summary

2) Introduction

i. Details of the EIA Consultant including NABET accreditation

ii. Information about the project proponent

iii. Importance and benefits of the project

3) Project Description

i. Cost of project and time of completion.

ii. Products with capacities for the proposed project.

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

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

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

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

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

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

ix. Hazard identification and details of proposed safety systems.

x. Expansion/modernization proposals:

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

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

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

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

4) Site Details

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

6) Environmental Status

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

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

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

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

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

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

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

viii. Soil Characteristic as per CPCB guidelines.

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

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

xi. Socio-economic status of the study area.

7) Impact and Environment Management Plan

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

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

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

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

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

vi. Measures for fugitive emission control

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

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

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

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

185


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

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

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

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

8) Occupational health

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

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

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

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

9) Corporate Environment Policy

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

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

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

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

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

11) Enterprise Social Commitment (ESC)

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

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

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

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

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

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

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

4. Work zone monitoring arrangements for hazardous chemicals.

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

6. Action plan for odour control to be submitted.

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

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

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

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

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

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12. Details of incinerator if to be installed.

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

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

***

Virchow Drugs Limited TOR Compliances

Page 1

Compliance of Terms of Reference Compliance of Standard TOR for “Synthetic Organic Chemicals Industry (dyes and dye

intermediates; bulk drugs and intermediates excluding drug formation; synthetic rubber; basic organic chemicals, other synthetic organic chemicals and chemical intermediates” Issued by

MoEF&CC for EIA/EMP report for Projects/Activates requiring Environmental Clearance Under EIA Notification, 2006

S.No Compliance of Terms or Reference Response

A. STANDARD TERMS OF REFERENCE 1 Executive Summary Included in EIA report. 2 Introduction i. Details of the EIA Consultant including

NABET accreditation EIA Consultants: Team Labs and Consultants List of QCI/NABET Consultants: S.No.161

ii. Information about the project proponent Presented in Chapter 1 of EIA report at Page No. 1-1

iii. Importance and benefits of the project Presented in Chapter 1 of EIA report at Page No. 1-1

3 Project Description i. Cost of project and time of completion. Cost of Project for Proposed Expansion is 2

crores. ii. Products with capacities for the proposed

project. Presented in Chapter 1 of EIA report at Page No. 1-3

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

Presented in Chapter 1 of EIA report at Page No. 1-3. The proposed expansion is within existing plant site. Total land area (existing): 3 acres.

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

Presented in Chapter 6 of EIA report at Page No. 6-3

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

Presented in Chapter 6 of EIA report at Page No. 6-3

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

Presented in Environment Management Plan. Emissions: 1-8 to 1-10 Effluents: 1-2 to 1-7 Hazardous Waste: 1-11.

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

Total water required: 249.5 KLD Fresh water: 159.5 KLD Recycled water: 90 KLD Water Balance is Presented in Chapter of EIA report at Page No. 2-9

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

Presented in Chapter of EIA report at Page No. 2-1 to 2-8 Separate Annexure

ix. Hazard identification and details of proposed safety systems.

Presented in Chapter 6 of EIA report at Page No. 6-8 to 6-10.

x. Expansion/modernization proposals: a. Copy of all the Environmental Clearance(s)

including Amendments thereto obtained Copy of Environmental Clearance and status of compliance of conditions


Page 2

for the project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of the latest Monitoring Report of the Regional Office of the Ministry of Environment and Forests as per circular dated 30th May, 2012 on the status of compliance of conditions stipulated in all the existing environmental clearances including Amendments shall be provided. In addition, status of compliance of Consent to Operate for the ongoing existing operation of the project from SPCB shall be attached with the EIA-EMP report.

stipulated in EC presented in Annexure - I. Point wise compliance of Consent for Operate (CFO) Presented at Annexure – II.

b. 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.

Not Applicable

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.

Virchow Drugs Limited Sy. No. 639 (Part), IDA Bonthapally, Jinnaram Mandal, Medak District, Telangana. Proposed expansion is within existing plant site of area 3 acres.

ii. A topo sheet 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)

Presented in Chapter 1 of EIA report at Page No. 1-5.

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

Proposal is for expansion of manufacturing capacity within existing plant site.

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

S.No Latitude Longitude 1 17O39’25.12” 78O21’18.16” 2 17O39’23.32” 78O21’17.40” 3 17O39’23.05” 78O21’14.28” 4 17O39’24.34” 78O21’12.46” 5 17O39’25.46” 78O21’12.42” 6 17O39’27.54” 78O21’13.81”

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

Enclosed at Annexure - III

vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant area, greenbelt area, utilities etc. If located

Plant layout is presented in Chapter 1 of EIA report at Page No. 1-6


Page 3

within an Industrial area/Estate/Complex, layout of Industrial Area indicating location of unit within the Industrial area/Estate.

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

Photographs of Plant site is presented in Chapter 3 of EIA report at Page No. 3-2

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)

Plant layout is presented in Chapter 1 of EIA report at Page No. 1-6

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

Land use and Land Cover map of the study area is presented in Chapter 3 of EIA report at Page No. 3-6.

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

Presented in Chapter 3 of EIA report at Page No. 3-2 to 3-3

xi. Details of Drainage of the project upto 5km radius of study area. If the site is within 1 km radius of any major river, peak and lean season river discharge as well as flood occurrence Frequency based on peak rainfall data of 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)

Drainage pattern of the impact area is presented in Chapter 3 of EIA report at Page No. 3-14

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.

Proposal is for expansion of manufacturing capacity within existing plant site of area 3 acres.

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

Not Applicable. Expansion within existing site area.

5 Forest and wildlife related issues (if 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)

The present proposal is for expansion within existing plant site, however land use map is presented in Chapter 3 of EIA report at Page No. 3-8

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

There are no National Parks, Sanctuaries, Biosphere Reserves, Migratory Corridors of Wild Animals within the impact area of 10 km.


Page 4

project location and the recommendations or comments of the Chief Wildlife Warden-thereon.

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

Site-specific micrometeorological data presented in Chapter 3 of EIA report at Page No. 3-21 to 3-23

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

AAQ data presented in Chapter 3 of EIA report at Page No. 3-28

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.

AAQ data is presented in Chapter 3 of EIA report at Page No. 3-28 to 3-29

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.

Representative water samples were observed to be dry.

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

No. The site located at IDA, Bonthapally, Jinnaram Mandal, Medak District, Telangana.

11.53 Km away from Critically Polluted Area of Patancheru – Bollaram Industrial Estates

vi. Ground water monitoring at minimum at 6 locations shall be included.

Ground Monitoring locations presented in Chapter 3 of EIA report at Page No. 3-13 and 3-15.

vii. Noise levels monitoring at 6 locations within the study area.

Noise levels monitoring is presented in Chapter 3 of EIA report at Page No. 3-32.

viii. Soil Characteristic as per CPCB guidelines. Soil Characteristics is presented in Chapter 3 of EIA report at Page No. 3-8 to 3-9.

ix. Traffic study of the area, type of vehicles, The additional traffic generated due to the


Page 5

frequency of vehicles for transportation of materials, additional traffic due to proposed project, parking arrangement etc.

proposed expansion shall be 2 truck trips per day.

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

Flora and Fauna of the Impact area is presented in Chapter 3 of EIA report at Page No. 3-39 to 3-48

xi. Socio-economic status of the study area. Socio-Economic status of the impact area is presented in Chapter 3 of EIA report at Page No. 3-33 to 3-38

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.

Predictions of ground level concentrations using ISC-AERMOD using ISCST3 model is of the pollutants presented in Chapter 4 of EIA report at Page No. 4-16 to 4-23. There will be 2 truck trips per day after expansion. Emissions considered from transport of vehicles as line source.

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

Total effluent generated sent to “Zero Liquid Discharge “System and treated effluent reused for cooling tower make-up.

iii. Impact of the transport of the raw materials and end products on the surrounding environment shall 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.

There will be 2 truck trips per day. Truck transport Incidents and concerns are presented in Chapter 6 of EIA report at Page No. 6-28.

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.

Quantity, quality of effluent generated from different operation is presented in Environment Management Plan of EIA report at Page No. 1-2 to 1-7.

Effluent Treatment System (ZLD) is presented in Environment Management Plan of EIA report at Page No. 1-2 to 1-7

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

Presented in Environment Management Plan of EIA report at Page No. 1-8.

vi. Measures for fugitive emission control Presented in Environment Management


Page 6

Plan of EIA report at Page No. 1-15. vii. Details of hazardous waste generation and

their storage, utilization and management. Copies of MOU regarding utilization of solid and hazardous waste in cement plant shall also be included. EMP shall include the concept of waste-minimization, recycle/reuse/recover Techniques, Energy conservation, and natural resource conservation.

Presented in Environment Management Plan of EIA report at Page No. 1-11. Reduce, reuse and recycled concept is presented in waste-minimization, Energy conservation is presented in Environment Management Plan of EIA report at Page No. 1-17.

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

Ash generated from coal fired boilers is 18.74 TPD and same sent to brick manufacturers.

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.

0.99 acres developed for green area. Layout showing green belt development is presented in Environment Management Plan at Page No. 1-18 to 1-19.

x. Action plan for rainwater harvesting measures at plant site shall be submitted to harvest rainwater from the roof tops and storm water drains to recharge the ground water and also to use for the various activities at the project site to conserve fresh water and reduce the water requirement from other sources.


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

Total Capital Cost: Rs. 2 crores EMP Cost estimate: Rs. 1.678crores Recurring Cost on EMP: Rs. 1.342 crores. Details are presented in Environment Management Plan at Page no. 1-22.

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

Presented in Chapter 5 of EIA report at Page No. 5-8.

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

Disaster Management Plan is presented in Chapter 6 of EIA report.

Onsite and Offsite Disaster is presented in Chapter 6 of EIA .

8 Occupational Health i. Plan and fund allocation to ensure the

occupational health & safety of all contract and casual workers

Total: 7 Lakhs/annum PPE: 5 Lakhs/annum Health Check-up: 5 Lakhs/annum

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, colour vision and any other ocular defect) ECG, during pre placement and Periodical examinations give the details of the

Medical health check-up is Environment Management Plan of EIA report at Page No. 1-14 to 1-15.


Page 7

same. Details regarding last month analyzed data of above mentioned parameters as per age, 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,

Presented in Environment Management Plan of EIA report at Page No. 1-13 to 1-14

Suitable PPE is prescribed to the employees working in area where the conc. Exceeds PEL values. Simultaneously the project and R&D team are consulted to suggest mitigative measures and or engineering control measures.

The focus shall always be in ensuring concentration within PEL by adopting engineering controls as when requires.

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

Annual report of Health Status of workers is enclosed at Annexure

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.

Corporate Environment Policy is presented in Environment Management Plan of EIA report at Page No. 1-20.

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.

Environment engineer is responsible to bring to focus to higher management in case of deviation/ violation of the environmental or forest norms / conditions.

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.

Environment Management Cell is presented in Environment Management Plan of EIA report at Page No. 1-20.

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

No

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

The present proposal is for expansion in existing area of 3 cares.

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

cost) shall be earmarked towards the Corporate Social Responsibilities – Budget is presented in Environment Management


Page 8

Enterprise Social Commitment based on Public Hearing issues and item-wise details along with time bound action plan shall be included. Socio-economic development activities need to be elaborated upon.

Plan of EIA report at Page No. 1-16.

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, 1986 or relevant Sections of Air and Water Acts? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.

No Individual Court case against the Project.

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

Enclosed at Compliance of Terms of Reference along with EIA & EMP.

B. SPECIFIC TERMS OF REFERENCE FOR EIA STUDIES FOR SYNTHETIC ORGANIC CHEMICALS INDUSTRY (DYES & DYE INTERMEDIATES; BULK DRUGS AND INTERMEDIATES EXCLUDING DRUG FORMULATIONS; SYNTHETIC RUBBERS; BASIC ORGANIC CHEMICALS, OTHER SYNTHETIC ORGANIC CHEMICALS AND CHEMICAL INTERMEDIATES)

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

Details of solvents used and balance is presented in Chapter 2 of EIA report at Page No. 2-17 to 2-18.

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

No process emission will generate from proposed expansion.

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

AAQ data is presented in Chapter 3 of EIA report at Page No. 3-28

4 Work zone monitoring arrangements for hazardous chemicals.

Presented in Chapter 5 of EIA report at Page No. 5-8 to 5-9.

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

Details of Effluent Treatment System (ZLD) are presented in Environment Management Plan.

6 Action plan for odour control to be submitted. Presented in Environment Management Plan of EIA report at Page No. 1-10.

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

Enclosed at Annexure - IV

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


9 Action plan for utilization of MEE/dryers salts. Salts generated from MEE/ATFD sent to TSDF.

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

Enclosed at Annexure

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


12 Details of incinerator if to be installed. Not Applicable. Organic waste sent to cements plant for co-incineration.


Page 9

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

Presented in Chapter 6 of EIA report

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




Status of compliance of the conditions stipulated in the Environmental Clearance



STUDIES AND DOCUMENTATION BYTEAM Labs and Consultants B‐115‐117 & 509, Annapurna Block, Aditya Enclave, Ameerpet, Hyderabad‐500 038. Phone: 040‐23748 555/23748616, Telefax: 040‐23748666





4. ANNEXURES






VIRCHOW DRUGS LIMITED

Compliance report of CFO

SCHEDULE-B

S.No 1 The Industry shall not manufacture any un-

consented products and exceeding capacities without obtaining Consent for Establishment (CFE) and Consent for Operation (CFO)

Noted the condition

2 The industry shall file the water cess returns in Form-1 as required under section (5) of Water (Prevention and control of pollution) Cess Act, 1977, on or before the 5th of every calendar month, showing the quantity of water consumed in the previous month alongwith water meter readings. The Industry shall remit water cess as per the assessment orders as and when issued by Board. The industry shall provide separate water meters with necessary pipeline for assessing the quantity of water used for each of the purposes as per Cess Form-I

Noted the condition, we are remitting the water cess and returns are submitted in Form-I to HO&RO-II.

3 The industry shall take steps to reduce water consumption to the extent possible and consumption shall NOT exceed the quantities mentioned below.

Water consumption is below the limits mentioned in the order

4 The emissions shall not contain constituents in excess of the prescribed limits mentioned below.

The emission standards prescribed under the act are complied.

5 The industry shall comply with ambient air quality standards of PM10

We comply with ambient air quality standards as specified under the act.

6 The industry vide letter dt.09.10.2013 stated that there are no process emissions in the manufacturing process and so scrubber was not provided. In case any change in their process, the industry shall obtain permission of the Board.

We donot have process emmissions. For fugitive emmissions control one scrubber is provided.

7 The industry shall provide online VOC

analysers and connect the data to APPCB website within 3 months, as committed vide letter dt.09.10.2013

Noted the condition.

8 The industry shall provide dyke wall to all storage tanks within 1 month, as committed vide letter dt.09.10.2013

All the tanks are provided with dyke walls.

9 The Industry shall provide digital flow meters for FE feed and FE condensate within 3 months, as committed vide letter dt. 09.10.2013.

Digital flow meters are provided

10 The industry shall submit bank guarantee of Rs.50,000/- with validity of 3 years for development of additional green belt of 0.8 Acre to meet the norms, at Regional Office, RC Puram, Medak district.

Green belt is developed as per the norms

11 The industry shall earmark an amount of Rs.2 lakhs per annum for 10 years towards the Enterprises Social Responsibility (ESR) activities and spend the amount in Local area.

We are spending the amount as per the directions in our local area.

12 The industry shall explore possibility of recovery of salts such as Ammonium sulphate, Sodium Sulphate etc., from the effluents generated by way of segregation of streams instead of evaporation of combined effluents and sending the salts to the TSDF for landfill.

R&D efforts are on regarding the possibility of recovery of salts from effluents

13 There shall not be any spillages/discharges of chemicals/effluents on ground. The drums containing chemicals & wastes shall be stores in elevated platform provided with leachate/spillages collection pit.

Noted and follwed the condition

14 The Industry shall maintain the following records and the same shall be made available to the Board Officials during the inspection.

a. Daily production details RG-I records and Central Excise Returns

b. Quantity of effluents generated, forced evaporated, first fore run & secondary condensate generation of daily basis.

c. Daily solid waste generated and disposed to TSDF

d. Log books for pollution control systems.

Noted the condition.Records are maintained and are available for inspection.

15 Regular monitoring of vents of the storage tanks and work room concentration shall be carried out using sensors

Yes, followed.

16 The proponent shall not use odour causing substances or Mercaptans and cause odour nuisance in the surroundings

We are not using any odour causing substances.

17 The industry shall operate Solvent Recovery Plant within plant premises. Solvents shall be recovered to the maximum extent possible and shall be reused. The industry shall submit status of efficiency of Solvent Recovery Plant to the concerned Regional Officer. The Industry shall not dispose spent solvents/mixed spent solvents to the traders/recyclers.

Solvents are recovered and reused in process. Recovery is above 95 %.

18 The evaporation losses in solvents shall be controlled by taking all preventive measures such as circulation of chilled brine, transfer of solvents by using pumps instead of manual handling closed centrifuges, providing primary and secondary condensers to all the reactor vents and all the solvents storage tanks and keeping solvent storage in ground storage tanks with closed pipeline to Reactors.

Pumps are used for transfer and vent condensers with chilled water circulation are provided.

19 As per G.O.Rt.No.286, the industry shall transport the industrial effluents and plying on the roads is allowed between 6 A.M. to 6 P.M only, if the industry is engaged in sending the effluents to CETP in the stipulated time frame.


20 The applicant shall submit Environment statement in Form-V to the Regional office before 30th September of every year as per rule No.14 of E(P) rules, 1986 & amendments thereof.

Form V is submitted to RO-II every year before 30 th september.

21 The industry shall comply with ‘Task force directions issued by Board from time to time.


22 All the rules & regulations notified by Ministry of Law and justice, government of India regarding Public Liability Insurance Act, 1991, should be followed.

Noted the condition and followed.

23 The conditions stipulated in this order are without prejudice to rights and contentions of this Board in any Hon’ble court of law.

Noted the condition

SCHEDULE –C (see rule 5(4))

(CONDITIONS OF AUTHORISATION FOR OCCUPIER OR OPERATOR HANDLING HAZARDOUS WASTES)

1 The Industry shall give top priority for waste minimization and cleaner production practices

We are giving top priority for waste minimization and cleaner production practices.

2 The industry shall not store hazardous waste for more than 90 days as per Hazardous Wastes (Management Handling ad Transboundary Movement) rules, 2008 and amendments thereof. The industry shall maintain 6 copy manifest system for transportation of waste generated and copies of receipt of consignee shall be submitted to the Concerned Regional Office. The Industry shall maintain proper records for Hazardous Wastes stated in authorization in FORM-3 i.e. quantity of Incinerable waste, land disposal waste, recyclable waste etc. and file annual returns in Form-4 as per rule 22(2) of the Hazardous Wastes (Management,Handling & Transboundary Movement) rules, 2008 and amendments thereof.

Noted the condition. We are maintaining 6 copy manifest system for transporting waste and is submitted to RO-II. Records for Hazardous waste are maintained and returns are filed in Form-4.

3 the Industry shall dispose/sell the Hazardous Waste to only industries/agencies authorized by the State Pollution control Boards. The industry shall verify the authorization of the Board given to the party before disposing its waste to the External Party.

Noted the condition and followed

4 The industry shall maintain proper records for Hazardous Wastes disposal and its concurrence with authorization. In case of variation in generation, industry shall submit explanation and obtain amendment in Environmental clearance/CFE/CFO in this regard

Noted and maintaining records

5 The industry shall store used/waste oil and Used Lead Acid Batteries in a secured way in their premises till its disposal. Waste oils shall be disposed to the authorized reprocessors/recyclers and used lead acid batteries shall be disposed to the manufacturers/dealers on buyback basis. The industry shall take necessary practical steps for prevention of oil spillages and carry over of oil from the premises. The industry shall check the certificate/authorisation/order of MoEF issued to the Re-users/recycle units while disposing the waste oil.

Waste oil is stored in drums, and all precautions taken to avoid oil spillages. Followed MOEF order.

6 The industry shall dispose of e-waste to the authorised recyclers only

Noted the condition

7 The industry shall conform to the co-processing guidelines of CPCB in sending wastes to co-processing for cement plants.

Noted the condition

8 The industry shall maintain good house keeping

Maintaining good house keeping

9 The industry shall submit the condition wise compliance report of the conditions stipulated in Schedule B & C of this order on half yearly basis to Board Office, Hyderabad and concerned Regional Office.

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1

GOVERNMENT OF ANDHRA PRADESH ABSTRACT

Promotion of Industries – Declaring Gaddapotharam (Kazipally), Bonthapally & Gundlamachnoor areas as Notified Industrial Areas – Orders Issued. --------------------------------------------------------------------------------------------------------------------

INDUSTRIES & COMMERCE (IP) DEPARTMENT

G.O.Ms. No. 120 Dated. 22.10.2013.

Read the following:

1. Letter No. Nil, dated 14/08/2012 of the President, Model Industrial Association, Hyderabad.

2. Letter No. Nil, dated 02/09/2013 of the President, Bulk Drug Manufacturers Association, Hyderabad.

3. Recommendation of the Committee constituted for this purpose 4. Single File No.29/1/2012/13884 of Commissioner of Industries, dated

11.10.2013 5. D.O.Lr.No.15/36/2013/EP (Engg./Pharma), Dated:30-04-2013 of the Commerce

Secretary to Government of India 6. G.O.Ms.No.64,EFS&T(ENV),Dated:25/07/2013

*** ORDER:

1. In the reference 1st & 2nd read above, the President, Model Industrial Association, Hyderabad and President, Bulk Drug Manufacturers Association (BDMA) have submitted representations for declaration of Gaddapotharam (Kazipally), Bonthapally & Gundlamachnoor industrial areas as the notified industrial areas, informing that the members of their associations have set-up Chemical and Pharma industries in five industrial pockets in the area viz. Khazipally-Gaddapotharam, Bonthapally, Bonthapally-Domadugu, Borapatla and Gundlamachnoor, way back in 1990s after getting all the required permissions and approvals including Consent for Operations (CFO). He has requested the Government for notifying the said locations as industrial areas so as to facilitate the industries to avail various benefits being announced by the Central Government under the Industrial Infrastructure Up-gradation Scheme (IIUS) and also incentives announced, from time to time, by the State Government, as these areas have immense potential to develop further as a major manufacturing hub for pharmaceuticals and related chemical products.

]

2. It is further be noted that Andhra Pradesh, particularly Hyderabad, has emerged as a major player in the Bulk Drug Industry sector. There are about 266 bulk drug manufacturing companies in Andhra Pradesh, of which 90 per cent are located around Hyderabad. Hyderabad is contributing about 35% of the country’s bulk drug production and has been labeled as Bulk Drug capital of India. The Commerce Secretary, Government of India, in the reference 5th cited has stated that the share in export of bulk drugs and pharmaceuticals from the state of Andhra Pradesh is about 30% of the total exports from the country and recommended for expansion of the existing units subject to compliance of Andhra Pradesh Pollution Control Board norms in order to give further boost to the exports from this sector.

3. In the reference 6th read above the Government permitted the existing Bulk Drug and Bulk Drug intermediates manufacturing units only subject to the installations of Zero Liquid Discharge (ZLD) facilities by such units to go for expansion duly complying with all extant environmental and other norms.

4. The matter was carefully examined by an expert committee constituted by the Commissioner of Industries which submitted its recommendations vide the reference 3rd read above. Based on their recommendations the Commissioner of Industries has submitted his recommendations vide the reference 4th read above.

2

-2-

5. The Government after careful examination of the matter and in view of the recommendations of the Commissioner of Industries, A.P., Hyderabad and under various provisions of the Industrial Investment Promotion Policy 2010-15 (IIPP 2010-15), hereby decided to notify the following areas as Notified Industries Areas, as these areas are already located within Manufacturing Zones as notified in the master plan of Hyderabad Metropolitan Development Authority and more than 140 industries are operating in these areas with all the required clearances including Consent for operations (CFO).

S.N Location Village Survey Nos Area in Ha. Full Part

1

Kazipally-

Gadda potharam Area

Kazipally --- 180 99.41

Gaddapotharam 12 to 16 7 to 10 , 25 , 28, 52 138.3

Alinagar 5, 12 to 17,20 to

27,30, 31, 32, 36, 41 ,43 to 48

9,11,18,19,27/1,30, 32 to 34, 41, 42, 47, 52

97.71

2 Bonthapally

Bonthapally 3,4,631,632,634,635

2,599,629,630, 633,

636, 637, 639,660

56.56

3 Bonthapally-DomaduguArea

Bonthapally 205-208,213-224, 227-229, 231, 232, 254, 256, 265, 272, 471, 472, 490/2

192,202,203, 204, 209, 225,226,233,235-238, 250-253,255,257-262, 264,266-271, 273, 274, 466-470, 473-475,487-489, 490/1,497, 626

40.76

Domadugu 290, 347, 348, 351, 354, 355, 357-363, 365

289, 291, 292, 341 , 345, 346, 349, 350, 352, 353, 356 ,366, 367, 369, 371, 372

38.40

4 Bodupatla Bodupatla 4 to 15, 24, 28, 29, 374, 375, 379/2, 388-390, 392-396

3,16,17,30,31,269 to 272, 373, 376 to 378, 385, 391,397

32.304

6. Further, it is noted that though the Industries located in Gundlamachanoor have

converted their lands for industrial use, the same has not been reflected in the master plan of Hyderabad Metropolitan Development Authority as manufacturing zone. The Bulk Drug Manufacturers Association vide their Letter No. BDMA/Commissioner/MPDA/2013-14 dated. 21-09-2013 have requested the Commissioner, Hyderabad Metropolitan Development Authority to correct the anomaly by notifying the above location as Manufacturing Zone. Therefore, the following location is also notified as Industrial area subject to notification of the area as Manufacturing Zone by the Hyderabad Metropolitan Development Authority in their master plan.

3

1 Gundla machnoor

Gundla machnoor

374, 375, 376, 377, 378 & 379

44.51

-3- 7. The following conditions will apply:

(a) All the industries coming within these locations must have a valid Consent for Operation (CFO) issued by A.P. Pollution Control Board as on the date of notifying as Industrial Area.

(b) The location including the areas of different survey numbers shall be within the manufacturing zone of the Hyderabad Metropolitan Development Authority Master Plan.

(c) All other clearances, approvals, approvals under various applicable laws, acts and rules of all relevant departments as required shall be applicable to all the industries coming within these notified locations; and

(d) All new industrial units proposed in the proposed Industrial Areas to be notified and those attract the provisions of Water (Prevention and Control Pollution) Act, 1974 and Air (Prevention and Control Pollution) Act, 1981, shall invariably obtain prior Consent for Establishment (CFE) from A.P. Pollution Control Board.

8. The Commissioner of Industries, Hyderabad shall take necessary action, in the matter.

(BY ORDER AND IN THE NAME OF THE GOVERNOR OF ANDHRA PRADESH)

K.PRADEEP CHANDRA, PRINCIPAL SECRETARY TO GOVERNMENT AND COMMISSIONER FOR INDUSTRIAL PROMOTION

To The Commissioner of Industries, A.P., Hyderabad. The MA & UD Department The EFS & T Department The Member Secretary, Andhra Pradesh Pollution Control Board, Hyderabad The Vice Chairman & Managing Director, APIIC, Hyderabad. The PR & RD Department The DT & CP Department The Revenue (CT) Department. The Energy Department. The Irrigation (Reforms) Dept. The Ind. & Com. (INF) Department. The Chairman & Managing Director, APTRANSCO., Hyderabad The Managing Director, APCPDC Ltd., Hyderabad The District Collector, Medak District.

//FORWARDED::BY ORDER//

SECTION OFFICER



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