M/s. Somu Chemicals and Pharmaceuticals Pvt Ltd., · PDF fileM/s. Somu Chemicals and Pharmaceuticals Pvt Ltd., - 1 - ... 2 Curcumin 3 MT Herbal Extracts ... Butyric acid 194 648 7776

M/s. Somu Chemicals and Pharmaceuticals Pvt Ltd.,

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CHAPTER 1

EXECUTIVE SUMMARY 1.1 INTRODUCTION

1.1.1 Preamble Amendment of the Environmental Impact Notification No. S.O. 60(E) dated

27.01.1994, issued by the MoEF, Govt. of India has made mandatory under

Schedule-I of EIA notification for 30 different activities to obtain NOC (No

Objection Certificate) from the State Pollution Control Board and

Environmental Clearance from the Ministry of Environment & Forests, Govt. of

India. This amendment to the EIA Notification is effective from 14.09.2006. It is

in this context that all such activities need to prepare Environmental Impact

Assessment (EIA) report and also appear before Public Hearing to ascertain the

response of Public for the project based on the general and specific conditions

of amended in said notification.

M/s. Somu Chemicals and Pharmaceuticals Pvt Ltd.,#20, 29th main, 1st phase, 2ndstage B.T.M layout Bangalore-76 intends to establish an Herbal Extract and Active Pharmaceutical Ingredients (APIs) & Intermediates manufacturing

industry with R&D activity at Shed No: B4 & B5, KSSIDC Industrial Estate,Veerasandra II Stage, Hosur Road, Anekal Taluk, Bangalore -560 100.

The APIs and Intermediates proposed to be manufactured are provided under section 1.1.2 (Project at Glance)

Sl. No.

Products Production capacity

(kg/annum)

Nature/ Type of product

A Herbal Extracts

1 Coleus Forskholii Extract 6 MT Herbal Extract

2 Curcumin 3 MT Herbal Extracts

3 Tetrahydrocurcuminoids 3 MT Cosmetic Ingredient

4 Piperine 1 MT Herbal Extract

5 Tetrahydropiperine 1 MT Cosmetic Ingredient

Total 14 MT----A

B Cosmetics ingredients, Neutraceutical Ingredients, Pharama Intermediates and API

1 Benzalkonium chloride 4 MT personal care

2 4-n Hexylresorcinol 3 MT Cosmetic Ingredient

3 4-n Butylresorcinol 2 MT Cosmetic Ingredient

4 2-Methylresorcinol 1 MT Cosmetic Ingredient

5 1,4-Cyclohexanedione 6 MT Intermediate

6 Tamsulosin HCl and its 1 MT API


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Intermediates

7 1-Chloromethyl Naphthalene 10 MT Intermediate

8 Piroctone Olamine 12 MT Cosmetic Ingredient

9 2 Ethyl Trizone 6 MT Cosmetic Ingredient

10 Benzethonium chloride 2 MT Cosmetic Ingredient

11 Iscotrizinol 2 MT Cosmetic Ingredient

12 Tinosorb S 1 MT Cosmetic Ingredient

13 Tinosorb M 1 MT Cosmetic Ingredient

Total 51 MT----B

Grand Total (A+B) = 65 MT

1.1.2 PROJECT AT GLANCE:

Sl.No. Details

1 Project Establishment of Herbal extract and Active Pharmaceutical Ingredients (APIs) & Intermediates manufacturing industry with R&D activity – “M/s. Somu

Chemicals and Pharmaceuticals Pvt Ltd.,

2 Project developers M/s. Somu Chemicals and Pharmaceuticals Pvt Ltd.,

#20, 29 th main, 1st phase, 2ndstage B.T.M layout Bangalore-76.

3 Location of the site

Shed No: B4 & B5, KSSIDC Industrial Estate, Veerasandra II Stage, Hosur Road, Anekal Taluk, Bangalore -560 100.

4 Constitution of the Organization

Private Limited Company

5 Raw materials Details of the raw materials required by the industry is appended in Section 3.5.2, Chapter 3 of this report.

6 Product/s proposed to be

manufactured with production capacities?

The following APIs and Intermediates are proposed to be manufactured

Sl. No.


(kg/month)

Production capacity

(kg/annum)

A Herbal extract

1 Coleus Forskholii Extract

500 6000

2 Curcumin 250 3000

3 Tetrahydrocurcuminoids 250 3000

4 Piperine 83 1000

5 Tetrahydropiperine 83 1000

Total 1,166 14,000--A

B Cosmetics ingredients, neutraceutical ingredients,

pharma intermediates and API

1 Benzalkonium chloride 334 4000


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2 4-n Hexylresorcinol 250 3000

3 4-n Butylresorcinol 167 2000

4 2-Methylresorcinol 83 1000

5 1,4-Cyclohexanedione 500 6000

6 Tamsulosin HCl and its Intermediates

83 1000

7 1-Chloromethyl

Naphthalene

833 10000

8 Piroctone Olamine 1000 12000

9 2 Ethylhexyl Trizone 500 6000

10 Benzethonium Chloride 167 2000

11 Iscotizinol 167 2000

12 Tinosorb S 83 1000

13 Tinosorb M 83 1000

Total 4,250 51,000--B

Grand Total (A+B) 65,000 kg/Annum or

say 65MT/Annum

7 Project cost? Sl No

Particulars Cost of the project in Rs (Lakh)

1. Land and Building 144.00

3. Plant & machinery 182.00

4. Office equipment 3.00

5. Furniture & fixtures 10.00

6. Environment Management Budget

3

Grand total 342.00

Rupees Three Crores Forty Two Lakhs Only

8 Total man power requirement during

construction phase

occupancy

phase

Construction phase: 25 people during peak construction period. Occupancy/Operational phase: 40 employees.

9 Proposed trees to

be planted?

Trees proposed to be planted – 50

10 Species of trees to

be planted?

Mango, Neem trees, Michelia champaca, Butea

monosperma, Pongamia

11 Rain water

harvesting tank details?

12 KL capacity

12 Groundwater recharging pits details?

1.2 m dia x 2.5 m deep spaced at 10 m center to center all along the storm water drain.


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13 Elevation of the

project site with respect to MSL?

Latitude: 12°50'51.89"N; Longitude: 77°41'21.33"E

922 m above MSL;

14 Total area of the

project?

10,000 sq ft

15 Hydrology and

hydrogeology?

Raysandra Lake at a distance of about 3 km towards

North west direction, Chika togur Lake at a distance of about 3 km towards West direction, Veersandra Lake at a

distance of about 2 km towards South west direction, Hebbgodi Lake at a distance of about 2.5 km towards South direction, Kamsandra Lake at a distance of about

2.5 km towards South East direction.

16 Ground water

quality?

Potabilty of water has to be tested.

17 Noise levels? Noise levels are to be tested.

18 Facilities provided for the workers

during construction phase at site?

1. Adequate potable drinking water supply 2. Domestic wastewater generated will be treated in

Septic tank and soak pit

1.1.3 Summary of water, wastewater, air & solid waste details

Sl. No.

Particulars Details

A Water, wastewater details

1 Water supply sources Bore well and Tanker water supply

2 Total water requirement 12 KLD

3 Total wastewater generated

8.77 KLD

4 Treatment/ Disposal details

Effluent generated from the project will be sent to Common effluent Treatment

Plant(CETP)

B Air pollution details

1 Sources of air pollution Process sections, Boiler, DG sets

2 Air pollution control

units provided

* Packed column scrubbers for process

sections with Chimney height of 5 m above RL.

* DG set stackt height as per the stack height calculation for 63.5 KVA is 7 m above RL.

* For diesel based fuel boiler for 0.6 Tons stack height of 17 m above RL

and with Scrubber.


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C Solid/Hazardous wastes

1 Source of solid waste Domestic sources and Manufacturing process.

2 Total quantity of solid waste generated

Domestic solid waste – 10 kg/annum Hazardous solid waste

Sl. no

Hazardous waste Quantity kg/annum

1 Residue from the manufacturing process – (solvent

recovery)

4500

2 Spent Carbon 1939 kg

3 HDPE containers 600 nos

4 Waste oil

generation from DG set

240L

5 Inorganic salts 3000

3 Treatment/Disposal of

solid wastes

* The domestic wastes are segregated at

source and collected in bins. The organic portion of the solid wastes will

be composted and recyclable portion will be disposed to the recycler for scientific recycling.

* The disposal optioclingns for various types of generated hazardous waste

handling and management is detailed in Chapter 3, Section 3.9.5 of this report.


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1.1.4 Water requirement and wastewater treatment and discharge details

i) QUANTITY OF WATER REQUIRED AND WASTEWATER GENERATED

The total quantity of water requirement for the industry is about 12 KLD. The break-up of the consumption of water is as presented in table below.

Water consumption and discharge

Sl. No.

Purpose Total Quantity LPD

Recirculation /Recycle LPD

Loss/Consumption(Evaporation Etc.)

(Daily Make Up Water)

LPD

Wastewater Generation In LPD

I Domestic (Toilet, Canteen etc.)

1800 - 1800 1620

II. Gardening/Landscape development

1,000 - 1000 -

III Industrial purpose 23,800 14500 9200 7150

1 Process 3000 - 3000 3000

2 Washing/

Cleaning

2,000 - 2000 2,000

4 DM water with R & D

500 - 500 500

3 Softener/rejects 8000

(7000-6300=700 )

6300 700 Make

up water +1000 for

softner

1150

(Softener rejects and boiler blow-

down)

Boiler feed for 600 Kg/hr 2 nos boiler

5 Cooling tower – 1 no.

10,000 (10,000-

8400=1600)

8400 1600 Make up water

200 (bleed off)

6 Scrubber – 1 no. 400 - 400 400

Grand Total 26,600 14,700 12,000 8870

Note:

LPD = L/day; KLD = kilo liter/day The excess quantity of process effluent generated is due to the reactions

taking place during the manufacturing process


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ii) WASTEWATER TREATMENT AND DISPOSAL DETAILS

The treatment methods and the final disposal of each type of wastewater generated is appended in the table below

Sewage/wastewater treatment and discharge

Sewage/effluent generated from

Treatment units provided Final disposal point

(a) Domestic The wastewater generated will be treated in septic tank

and soak pit.

Recycle and on land irrigation.

(b) Industrial The effluent is collected in

the collection tank and send to CETP.

Industrial effluent is sent to

common effluent treatment plant (CETP) for treatment and disposal.

1.1.5 RAW MATERIALS The raw materials required for the manufacture of APIs and Intermediates are

appended in the table 1.0 below. Raw materials as listed will be procured as per the production requirement.

Table1.0: Raw materials requirement

Sl.

No.

Product Raw

materials

Quantity required Solvents

required after recycling

kg/annum

kg/ batch

kg/ month

kg/ annum

A Herbal Extract

1 Coleus forskholii extract

Coleus roots powder

1000 10,000 12,000 -

Toluene 3000 30,000 3,60,000 10800

Hexane 300 3000 36000 1800

Dextrin 25 250 3000 -

2 Curcumin Vanillin 111 278 3336 -

Acetyl acetone

37 93 1116 -

Boric oxide 18 45 540 -

TSBB 205 513 6156 -

n-Butylamine 9 23 276 -

Ethylacetate 675 1688 20256 900

Water for process

1675 4188 50256 -

Water for reactor washing

500 1250 15000 -


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3 Tetrahydro

Curcuminoids

Curcuminoid

s

166 415 4980 -

Acetone 1660 4150 49800 2400

Palladium Carbon

8 20 240 -

IPA 500 1250 15000 750

H2 Cylinder 3 8 96 -

N2 Cylinders 1 3 36 -

Water for

reactor washing

500 1250 15000 -

4 Piperine Methyl Bromocrotonate

100 104 1248 -

Triethyl Phosphite

95 99 1188 -

Piperidine 65 68 816 -

DMF 300 312 3744 -

Sodium Methoxide

10 11 132 -

Methanol 500 520 6240 -

Water for Process

700 728 8736 -

Water for reactor

washing

500 520 6240 -

5 Tetrahydropipe

rine

Piperine 71 118 1416 -

Acetone 710 1179 14148 698

Palladium

Carbon

3.5 6 72 -

IPA 215 357 4283 199


N2 Cylinder 1 2 24 -

Water for reactor

washing

300 498 5976 -

B Cosmetics ingredients, neutraceutical ingredients, pharama intermediates

and API

1

Benzalkonium

chloride

Amine 340 170 2040 -

DM Water 456 228 2736 -

Benzyl

chloride

204 102 1224 -


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Water for

reactor washing

500 250 3000 -

2 4-nHexyl

Resorcinol

Resorcinol 100 500 6000 -

Caproic acid 200 1000 12000 -

Zinc catalyst 10 50 600 -

Raney Nickel 10 50 600 -

Methanol 500 2500 30000 1500

Hexane 500 2500 30000 1500


N2 Cylinders 1 5 60 -

Water for Process

600 3000 36000 -

Water for reactor

washing

500 2500 30000 -

3 4-nButyl

Resorcinol


Butyric acid 194 648 7776 -

Zinc catalyst 11.1 37 444 -

Raney Nickel 11.1 37 444 -

Methanol 555 1854 22248 1800

Hexane 555 1854 22248 1500



Water for Process

600 2004 24048 -

Water for

reactor washing

500 1670 20040 -

4 2-methyl resorcinol

1,3-Cyclohexane

dione

158 131 1572 -

Dimethylamine

158 131 1572 -

Formaldehyde

150 125 1500 -

Palladium on Carbon 5%

48 40 480 -

Hydrochloric acid

121 100 1200 -

Mesitylene 1425 1183 14196 -

Water for

process

600 498 5976 -


- 10 -

Water for

reactor washing

500 415 4980 -

5 1,4-

cyclohexanedione

Dimethyl

Succinate

333 1665 19980 -

Sodium

Methoxide

187 935 11220 -

Methanol 720 3600 43200 2160

Con .Sulphuric

acid

170 850 10200 -

Ethyl acetate 1670 8350 1,00,200 4800

Charcoal 13 65 780 -

Water for

process

1200 6000 72,000 -

Water for

reactor washing

600 3000 36,000 -

6 Tamsulosin HCl

5(2-Amino-Propyl)2-Methoxy-

Benzene-Sulphonamide

27.5 91.3 1096 -

2-(O-ethoxy-Phenoxy)

ethyl bromide

25 83 996 -

Sodium

Carbonate

17 56 672 -

Isopropyl

alcohol

125 415 4980 241

Ethyl acetate 175 581 6972 321

Methanol 140 465 5580 281

Charcoal 0.5 1.66 20 -

Con Hcl 7.5 25 300 -

Water for

process

70 233 2796 -

Water for

reactor washing

100 334 4008 -

7 1-ChloroMethyl Naphthalene

Naphthalene 278 1390 16680 -

Para-

Formaldehyde

100 500 6000 -


- 11 -

Glacial Acetic

acid

290 1450 17400 -

Con .HCl 335 1675 20100 -

Ortho-Phosphoric

acid

160 800 9600 -

Water for

process

2000 10,000 120000 -

Water for

reactor washing

500 2500 30000 -

8 Piroctone Olamine

3,3'-DMAA 125 1250 15000 -

Isononanoyl

chloride

250 2500 30000 -

Anhyd.Aluminium

Chloride

500 5000 60000 -

Sodium

methoxide

125 1250 15000 -

Monoethanol

amine

12.5 125 1500 -

Hydroquinon

e

12.5 125 1500 -

Sodium

Carbonate

125 1250 15000 -

Glacial Acetic

acid

125 1250 15000 -

Methanol 750 7500 90,000 4440

Hydroxylamine Hcl

190 1900 22800 -

Con. Sulphuric acid

25 250 3000 -

Ethyl Acetate 1250 12500 150000 7200

EDC 750 7500 90000 4200

Water for process

1500 15000 180000 -

Water for reactor

washing

750 7500 90000 -

9 2 Ethylhexyl

Trizone

2-

Ethylhexanol

85 425 5100 -

Acetonitrile 610 3050 36600 1200


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Ammonia

25% Solution

6 30 360 -

Cyanuric chloride

25 125 1500 -

P-nitro benzoic acid

30 150 1800 -

Sodium chloride

6 30 360 -

Methanol 710 3550 42600 2100

Hexane 570 2850 34200 1800

Sodium Carbonate

6 30 360 -

PD/C 10% 5 25 125 -

Perchloroethy

lene

945 4725 56700 3300

Carbon 5 25 300 -

Sulphric acid 5.5 27.5 330 -

Xylene 400 2000 10000 1200

Water for process

1675 8375 100500 -

Water for reactor

washing

500 2500 30000 -

10 Benzethonium

Chloride

2-Octyl

Phenol

185 309 3708 -

Benzyl

chloride

100 167 2004 -

Diethylenegly

col

106 177 2124 -

Diethylamine (40%)

296 494 5932 -

Ethyl acetate 1400 2338 28056 1403

Phosphorous oxy chloride

125 209 2505 -

Sodium hydroxide

155 259 3106 -

Toluene 2670 4459 53507 1102

Water for process

1600 2672 32064 -

Water for reactor

washing

500 835 10020 -


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11 Iscotrizinol 2-Ethylhexyl

4-Aminobenzoate

100 167 2004 -

Acetonitrile 255 426 5110 200

Ammonia

25% Solution

41 69 822 -

Cyanuric

chloride

45 75 902 -

Dimethylform

amide

1 1.67 20 -

Hexane 540 902 10822 501

Methanol 420 701 8417 401

P-Nitro

benzoic acid

48 80 962 -

Potassium

Carbonate

19 32 381 -

Tert-

Butylamine

29 49 581 -

Carbon 1 1.67 20 -

Toluene 1210 2021 24248 902

Triethylamine 33 55 661 -

Water for process

1500 2505 30060 -


500 835 10020 -

12 Tinsorb S 2-Ethylhexyl Bromide

145 120 1444 -

4-Bromoanisole

80 65 797 -

Aluminium Chloride

125 104 1245 -

Cyanuric chloride

80 65 797 -

Dimethylformamide

590 490 5876 -

Hexane 110 91 1096 50

Ethylene

Dichloride

725 602 7221 359

Iodine 0.2 0.166 2 -

Isopropyl alcohol

1030 855 10259 548

Magnesium 14 12 140 -

n-Butanol 735 610 7320 349


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Methanol 85 71 847 50

P-Nitro

benzoic acid

10 8.3 100 -

Sodium

carbonate

150 125 1494 -

Tetrahydrofu

ran

400 332 3984 199

Carbon 3 2.5 30 -

Toluene 1790 1486 17828 897

Vitride (70%)

in Toluene

0.4 0.33 4 -

Water for process

1550 1287 15438 -

Water for reactor

washing

500 415 4980 -

13 Tinsorb-M 4-tert-

Octylphenol

143 119 1424 -

Acetic acid 56 46.5 558 -

Diethylamine 3.7 3 36.9 -

Methanol 600 498 5976 299

Hydrochloric acid (35%)

540 448 5379 -

o -Nitroaniline

95 79 946 -

Paraformaldehyde

8.5 7 84.6 -

Sodium Methoxide

7 6 70 -

Isopropyl alcohol

100 83 996 50

Sodium Hydroxide

110 91 1096 -

Sodium Nitrite

51 42 508 -

Sulfamic acid 4 3.3 39.6 -

Methanol 1600 1328 15936 797

Toluene 750 622.5 7470 349

Xylene 510 423 5079.6 249

Zinc Powder 85 70.5 846.6 -

Water for

process

1700 1411 16932 -


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Water for

reactor washing

500 415 4980 -

1.1.6 Solvent recovery and recycling:

Various solvents are proposed to be used during the manufacturing process. The solvents proposed to be recovered and recycled during the process of

recovering the solvent of such product are detailed in table 1.1 below.

Table: 1.1 Solvent recovery

Sl. No

Product Raw materials

Quantity (kg/annum)

Recovered and recycled

Lost

A Herbal Extract

1 Coleus Forskholli

extract

Toluene 3,49,200 10800

Hexane 34,200 1800

2 Curcumin Ethyl Acetate 19,350 900

3 TetrahydroCurcumin

oids

Acetone 47400 2400

IPA 14250 750

4 Piperine Methanol 5616 624

5 Tetrahydropiperine Acetone 13446 698

IPA 4084 199

B Cosmetics ingredients, neutraceutical ingredients, pharama intermediates and API

1 Benzal Koniumchloride

---

2 4-nhexylresercinol Methanol 28500 1500

Hexane 28500 1500

3 4-n Butylresercinol Methanol 21243 1002

Hexane 21042 1203

4 2- Methylresercinol Mesitylene 13496 698

5 1,4 cyclohexanedione Methanol 41040 2160

Ethyl acetate 95400 4800

6 Tasmsulosin HCL and its itermediates

Isopropyl alchol

4770 241


Methanol 5299 279

7 1-chloromethyl Naphthalene

----

8 Piroctone Olamine Methanol 85560 4440

Ethyl Acetate 146400 7200


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EDC 85800 4200

9 Ethylhexyl Trizone Acetonitrile 34800 1200

Methanol 40500 2100

Hexane 32400 1800

Perchloroeth

ylene

53400 3300

Xylene 22800 1200

10 Benzethonium Chloride


Toulene 52405 1102

11 Iscotrizinol Acetonitrile 4910 201

Hexane 10321 501

Methanol 8016 401

Toulene 23347 902

12 Tinosorb- S Hexane 1046 50

Ethylene Dichloride

6872 359

Isopropyl alcohol

9711 548

Methanol 797 50

Toulene 16932 897

13 Tinosorb -M Methanol 5677 299

Isopropyl

alcohol

947 50

Methanol 15139 797

Toulene 7121 349

Xylene 4831 249

Note: * The solvent lost during the process of solvent distillation is mainly due

to organic thermal disintegration and in form of residue left behind from the bottom un-distilled product. Evaporation loss is minimized by the passage of chilled brine solution and chilled water through the double condensor.

1.1.7 Air pollution details

The major air pollution sources from the industry are DG sets, boiler and process sections. These sources are provided with stacks of adequate height so

as to disperse the emanating flue gases containing SPM, oxides of sulfur and nitrogen without affecting the ground level concentrations and packed column scrubbers are proposed to the process sections with adequate stack height as

per the regulatory requirements.

The sources of air pollution, type of fuel used, fuel consumption and chimney heights for each of the air pollution sources of the proposed project are indicated in the following table 1.2.


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Table: 1.2 Air pollution sources, fuel consumption and chimney height details

SI. no.

Stack attached to Fuel used Fuel consumption

Number of

stacks

Stack/s height

Air pollution control unit

Predicted emissions

1 Process section - - 1 5 m

ARL

Packed

column scrubber 1 no.

Acid

mist/ VOCs

2 Steam boiler – 0.6 Ton/hr

capacity – 2 no.s

Diesel 45 L/hr 1 17 m AGL

Stack SO2, NOx, SPM

3 D.G. set 63.5

kVA – 2 no.

HSD 12.7 L/hr 1 7 m

AGL

Stack SOx, NOx,

SPM

* Stack height calculation for DGs Existing :

Formula adopted for stack height calculation

H = 14(Q)0.3

Where, H is stack height Above Ground Level Q is sulfur content in exhaust in kg/hr (As per Handbook on Environmental Legislations and Technologies)

Fuel consumption =12.7L/hr = 0.0127 m3/hr Sulfur content in HSD = 0.25% Density of sulfur = 2046 kg/m3

Therefore, Q = 0.0127 x (0.25/100) x 2046 = 0.0649 kg/hr Therefore, height of chimney = 14 (0.0649)0.3

= 6.16 m AGL Or say 7 m AGL Therefore it is proposed to provide 1 stack of height 7 m AGL for one diesel generator of 63.5 kVA capacity. ** STACK HEIGHT CALCULATION FOR BOILERS

Existing : Formula adopted for stack height calculation

H = 14(Q)0.3

Where, H is stack height Above Ground Level Q is sulfur emissions in kg/hr


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0.6 TPH BOILER Type of fuel used – diesel

Sulfur content in diesel is 1.8% Specific gravity of sulfur = 2.046

Density of sulfur = 2046 kg/m3 Fuel consumption = 45 L/Hour = 0.045 m3/Hr Therefore, Q = 0.045 x (1.8/100) x 2046 = 1.65 kg/Hr

Therefore, Height of chimney = 14 (1.65)0.3 = 16.26 m AGL Or say 17 m AGL

However a stack of height 17 m AGL is installed. 1.1.8 Noise pollution details

The major source of noise pollution in the industry is from DG sets for which acoustic enclosure is proposed. Also ambient noise levels will be ensured

within the ambient standards by inbuilt design of mechanical equipment and building apart from vegetation (tree plantations) along the periphery and at various locations within the industry premises.

1.1.9 Solid waste details:

The quantity of solid waste generated from the proposed industry is detailed in the following table 1.3.

Table: 1.3 Solid waste generation during the operation phase

Total no. of employees 40

Assuming per capita solid waste generation rate as 0.2 kg/capita/day

Quantity of solid waste generated 8 kg/day

Organic solid waste : 60 % of the total waste

5 kg/day

Inorganic solid waste : 40 % of the total waste

3 kg/day

Disposal of domestic solid waste The domestic wastes are segregated at source, collected in bins and composted.


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1.1.10 Hazardous raw materials used in the manufacturing process

The following raw materials used during the process of manufacture of APIs are hazardous in nature according to Manufacture, Storage and Import of Hazardous Chemical (Amendment) Rules, 19th January 2000, Schedule I, Part II in the table 1.4

Table: 1.4 Hazardous raw materials

Hazardous raw material Sl. No. as per Manufacture, Storage and Import of Hazardous Chemical (Amendment) Rules, 19th January 2000, Schedule I, Part II

Toulene 628

Hexane 306

Acetone 4

Piperdine 514

Benzyl chloride 67

Dimethylamine 215

Formaldehyde 295

Hydrochloric acid 313

Mesitylene 362

Sulphuric Acid 591

Ethyl Acetate 247

Isopropyl alcohol 334

Napthalene 417

Acetonitrile 7

Iodine 323

1.1.11 Hazardous waste generation and its management during the

manufacturing process

The hazardous wastes generated during the process manufactured of different

APIs are stored at hazardous waste storage area and sent to cement industries for co-incineration (as an auxiliary fuel) during the manufacture of cement.

The quantities of spent carbon generated from various processes are shown in the following tables 1.5.

1) Spent carbon

Table: 1.5 Quantity of spent carbon generation from manufacturing process

Sl. No.

APIs Quantity of spent carbon, kg/annum

1 Tetrahydro

Curcuminoids a. Palladium carbon

240


- 20 -

2 Tetrahydro piperine

a.Palladium Carbon

70

3 2 methyl Resorsinol a. Palladium carbon

478

4 1,4 Cyclohexanedion a. Charcoal

780

5 Tamsulin HCL a. charcoal

20

6 Ethylhexyl trizone a. carbon

300

7 Iscotrizinol a. carbon

21

8 Tinsorb S a. carbon

30

TOTAL 1,939

Spent carbon is used during the process of manufacture of different APIs & intermediates. The spent carbon will be disposed for co-incineration in cement

manufacturing are listed in the table below1.6. 2) Spent catalyst:

Table: 1.6 Quantity of catalyst generation from manufacturing process

Sl. No. APIs Quantity of catalyst generated, kg/annum

1. 4 n hexyl Resorsinol a. Zinc catalyst b. Raney Nickel catalyst

600 600

2. 4n butyl Resorsinol a. Zinc catalyst

b. Raney Nickel catalyst

445

445

Total 2,090


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3) Others : The various hazardous waste generated from the industry is

presented in table 1.7 Table: 1.7 miscellaneous types of hazardous waste generated

Sl. No.

Particulars Quantity of hazardous waste

generated kg/annum

Disposal Options Category

1 Waste oil generation

from DG set

240 L Disposed through

authorized recyclers

5.1

2 Residue from

solvent recovery plant

4500 Disposed through

Cement industries for co incinerations

28.1

3 HDPE Containers 6,00 nos Disposed through authorized recyclers

33.3

4 Inorganic salt 3,000 Dispoded to TSDF for scientific landfill.

34.3

5 Spent carbon 1,939 Disposed through Cement industries for co incinerations

28.2

1.1.12 Project setting

The project proponents will usually identify certain basic factors while selecting the site for the project. Such factors are usually related to the titles of the

property, commercial viability, location of the site, availability of raw materials and resources required etc. In addition to this the environmental setting of the

proposed location is also an important factor while deciding the site for a project. All these criteria are favorable for the establishment of M/s. Somu Chemicals and pharmaceutical Pvt. Ltd., since the project site is located at

KSSIDC Industrial Estate. The project well connected by Bangalore Hyderabad road at about 2 km NH 7.

Therefore the project site is well connected by roadways. Heelalige Railway Station is at a distance of about 4.5 km towards south east direction the

industry can be easily transported. From the view point of basic infrastructural facilities required for the industry

Viz. power supply, water supply and sanitation facilities will not be a problem as the industry is coming up in a designated industrial area. As far as the environmental setting is concerned the proposed project site is located at

KSSIDC industrial Estate, surroundings have villages, individual residential units, few commercial establishments.


- 22 -

The general topographical features of the area reveal that the proposed project site and its surroundings is generally a plain land with slight undulations.

This plot is located at an elevation of about 922 m above MSL, the climatic

conditions is temperate (semi arid) with moderate annual rainfall varies from 500 mm to 850 mm. Site bearings The proposed project site is surrounded by vacant plots/industrial plot in all directions.

Sl.No. Particulars Direction w.r.t. project site

1 Acess Road South

2 Road and Industrial shed North

3 Industrial sheds West

4 Industrial sheds East


- 23 -

1.2. ENVIRONMENTAL IMPACTS AND MANAGEMENT PLAN 1.2.1 Environmental management plan during construction phase

Sl. no.

Environmental components

Predicted impacts

Probable source of impact

Mitigation measures

Remarks

1 Ambient air quality

Marginal negative impact

inside the construction site

premises. No negative impact outside.

Fugitive dust emissions generated

during construction in the beginning

followed by fabrication, erection of plant and

machinery installations during later part of the

project.

Carrying out the

construction activities in

closed manner.

Intermittent

spraying of water.

Use of PPE.

Impacts are temporary (only during construction period) in

nature. Also the proposed project does not involve

extensive construction activities (total built-up area is 7,000 Sq ft); construction

is more of fabrication and erection type except admin, R & D and Watch and ward

buildings.

2 Noise Marginal

negative impact near noise

generation sources inside the premises. No

significant impact on the ambient noise

levels to the surrounding

area.

Noise generation from

construction activities and operation of

construction equipments and also from the movement of

vehicles carrying construction materials to and from the project

site.

Use of well

maintained equipment.

Use of PPE – ear plugs and muffs by the

construction workers.

Temporary impact only

during construction phase.

3 Water quality No significant

impact

Discharge of sewage

from laborers.

The sewage

generated shall be treated in

Impact will be

temporary. Local laborers shall be


- 24 -

septic tank and

soak pit

employed.

4 Land No negative impact

Waste from laborers. Waste from laborers will be

collected and composted on site.

Non-compostable waste will be disposed

scientifically.

-

5 Socio-

economic

Overall positive impact

Employment

opportunities

- -

1.2.2 Environmental management plan during operation phase

Sl. no.

Environmental components

Predicted impacts

Probable source of impact

Mitigation measures Remarks

1 Ambient air quality

Minor negative

impact.

Process of manufacture of

APIs, intermediates

Particulate and

gaseous emissions from

DG set and boiler

Manufacturing process involves closed operations in

various controlled reactors. The process area shall be

provided with abundant

natural light and ventilation and high roofs to disperse the

fumes/gases to the outside atmosphere; preventing the increase of ground level

concentrations (GLC’S) as it gets dispersed.

DG sets shall be used only during power

failure.


- 25 -

Packed column scrubbers are

proposed to neutralize and control dust and fumes from the process section.

The treated waste gases and fumes will be let out through stacks of 5 m height ARL.

The emissions from DG & boiler will be let out through

stacks of heights 7 m AGL and 17 m AGL respectively.

2 Noise Minor negative impact near

noise generation sources

inside the premises.

Operation of machineries during the

manufacturing process.

Handling and

conveying of raw materials

and semi-finished components to

different operations.

Operation of DG set.

The conveying system shall be maintained by following routine and periodic

maintenance to reduce noise generation in material handling.

DG set will be provided with acoustic enclosure. They will

be installed in dedicated utility area, where the access will be restricted. Also the use

of PPE (ear plugs) will be mandatory in this area.

Green belt at the project boundary will further act as noise barrier and help in

attenuation of noise.

-

3 Water quality No significant

adverse impact

Discharge of

domestic sewage and industrial effluent

Domestic sewage will be

treated in septic tank and soak pit.

The industrial effluent is

Water conservation

measures shall be encouraged.


- 26 -

proposed to be sent to

Common effluent treatment plant for treatment and disposal.

4 Land No negative impact

Discharge of wastewater.

Storage and disposal of solid wastes.

Domestic sewage will be treated in septic tank and soak pit.

The total quantity of domestic wastes generated which will be segregated at source, collected in

bins and composted. The composted waste will be used as

manure for landscape development.

-

5 Socio-

economic

Overall positive impact

Employment

opportunities

Locally available man power will be

utilized to the maximum possible extent.

-


- 27 -

CHAPTER 2

INTRODUCTION OF THE PROJECT/BACKGROUND INFORMATION

2.1 INTRODUCTION OF PROJECT PROPONENT M/s. Somu Chemicals and Pharmaceuticals Pvt Ltd.,#20, 29th main, 1st phase,

2ndstage B.T.M layout Bangalore-76 intends to establish an herbal extract and

Active Pharmaceutical Ingredients (APIs) and Intermediates manufacturing

industry with R&D activity at Shed No: B4 & B5, KSSIDC Industrial

Estate,Veerasandra II Stage, Hosur Road, Anekal Taluk, Bangalore -560 100.

2.2 BRIEF DESCRIPTION ABOUT THE NATURE OF THE PROJECT The proposed industry M/s. Somu Chemicals and pharmaceuticals Pvt. Ltd., is

a Private Limited company with Venkatesan as the technical Director. The industry is proposed to be established at Shed No: B4 & B5, KSSIDC Industrial

Estate,Veerasandra II Stage, Hosur Road, Anekal Taluk, Bangalore -560 100. The main activity of the company is to manufacture of herbal extract and

Active Pharmaceutical ingredients (API) & Intermediates. Somu Chemicals and Pharmaceuticals (P) Ltd., established in 2010, a new

grass root manufacturing unit at Veerasandra industrial estate near Bangalore with the aim of providing Health Care to everyone by manufacturing Standard

Herbal Extracts, Cosmetic intermediates, Nutraceutical products and fine chemicals. We are specialized in Condensation, Acetylation, Grignard reaction and

Hydrolysis process with a well established Quality Control and R&D center.

2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND/REGION

Bulk drugs have become a part of our life for sustaining many of our day-to-day activities, preventing and controlling diseases. Bulk drugs manufacturing sector in India is well established and has recorded a steady growth in the

overall Indian industrial scenario. The bulk drugs and allied industries have been amongst the fastest growing segments of the Indian industry.

The Indian Pharmaceutical Industry today is in the front rank of India’s science-based industries with wide ranging capabilities in the complex field of drug manufacture and technology. It is expected to reach a level of Rs 3200 billion by 2012. It ranks very high in the third world, in terms of technology,

quality and range of medicines manufactured. From simple headache pills to


- 28 -

sophisticated antibiotics and complex cardiac compounds, almost every type of medicine is now made indigenously.

Playing a key role in promoting and sustaining development in the vital field of

medicines, Indian Pharma Industry boasts of quality producers and many units approved by regulatory authorities in USA and UK. International

companies associated with this sector have stimulated, assisted and spearheaded this dynamic development in the past years and helped to put India on the pharmaceutical map of the world.

India's pharmaceutical industry is the third largest in the world in terms of

volume. Its rank is 14th in terms of value. India is also one of the top five active pharmaceutical ingredients (API)producers (with a share of about 6.5 per cent).

The pharmaceutical industry in India meets around 70% of the country's demand for bulk drugs, drug intermediates, chemicals, tablets, capsules, orals and injectibles. Between September 2008 and September 2009, the total turnover of India's pharmaceuticals industry was US $21.04 billion. The

domestic market was worth US $12.26 billion. This was reported by the Department of Pharmaceuticals, Ministry of Chemicals and Fertilizers. As per a

report by IMS Health India, the Indian pharmaceutical market reached US $10.04 billion in size in July 2010. A highly organized sector, the Indian Pharma Industry is estimated to be worth $4.5 billion, growing at about 8 to 9

percent annually.

The pharmaceutical industry in Karnataka contributes Rs. 350 crore in revenue to the State exchequer and provides employment for 12,000 people. Its growth rate is between 10-12 percent as against the national pharma growth of

12-14 percent. Pharma products worth Rs. 2,000 crore are produced annually, which is 10 percent of the national production. The exports sales are Rs.850

crore which is 8 percent of Indian exports. International pharma majors have preferred many companies from the State.

When large companies offer their services on contractual basis to global MNCs, they want to outsource drug production for the domestic market from quality

small-medium manufacturers in State. Here the small-medium units ideally fit into slot as third party manufacturers and serve as a major hubs for pharmaceutical outsourcing. In fact, two of Indian pharma sectors top five

brands, are already outsourced from Karnataka. The units have been recognised for stringent regulatory enforcement and known to manufacture quality products.

Another added advantage favoring the State is that it is emerging as an

investment destination.


- 29 -

Hence the proponents have proposed setting-up of the new pharmaceutical industry - M/s. Somu Chemical & Pharamaceutials Pvt. Ltd., at Shed No: B4 &

B5, KSSIDC Industrial Estate,Veerasandra II Stage, Hosur Road, Anekal Taluk, Bangalore -560 100.

2.4 DEMAND SUPPLY GAP, IMPORTS vs INDIGENOUS PRODUCTION

Indian pharmaceutical companies supply almost all the country's demand for API and nearly 70 per cent of demand for bulk drugs. The imports of pharmaceuticals are estimated at 10 to 12 percent of the total market. The

major suppliers are Switzerland, China, USA, Germany, Italy, Denmark, France, and UK. Imports include raw materials and finished products. Some

major pharmaceuticals which are imported include Provitamins and Vitamins, Cortisones, Hydrocortisone, Insulin, Penicillin, Osetrogen, Progesterone and other hormones, Erythromycin and other ANTIBIOTICS, Antisera & other blood

fraction, and Glycosides.

The imports are from Switzerland, US and Germany primarily consist of finished medicament in dosage forms for retail sales.

2.5 EXPORT POSSIBILITY: The size of the domestic pharmaceutical market is larger than export market.

However, owing to the growth of global generics market, stringent price controls in the domestic market, and better margins, the export market is

growing much faster than the domestic market. India exports pharmaceuticals to numerous countries around the world,

including to the U.S., Germany, France, Russia and UK. The Indian pharmaceutical industry ranks 17th with respect to exports value of bulk actives and dosage. Exports constitute nearly 40 per cent of the production,

with bulk drugs 45 per cent.

According to the Pharmaceutical Export Promotion Council (Pharmexcil), the pharmaceutical exports in 2007-08 stood at US $6.68 billion against US $5.73 billion in 2006-07, recording a growth rate of 16 per cent. The industry has

been clocking export growth rate, recording 18 per cent, 23 per cent and 17 per cent growth rates during 2006-07, 2005-06, and 2004-05, respectively. The

overall pharmaceutical exports are estimated to increase at a CAGR of 30-32 percent and reach US $ 18.3 billion in 2010 - 11.

2.6 EMPLOYMENT GENERATION DUE TO THE PROJECT The total direct employment potential of the proposed industry is about 40

people. However, there are indirect employment generation due to the project during the transportations, marketing & distribution etc


- 30 -

CHAPTER 3

PROJECT DESCRIPTION

3.1 TYPE OF PROJECT The main activity of the proposed industry is manufacturing of herbal extract

and Active Pharmaceutical Ingredients (APIs) and Intermediates with R&D Activity.

The total production capacity 65,000 kg/Annum.

3.2 LOCATION OF THE PROPOSED INDUSTRY The industry is proposed to be established at Shed No: B4 & B5, KSSIDC

Industrial Estate,Veerasandra II Stage, Hosur Road, Anekal Taluk, Bangalore -560 100.

Google map is appended as fig 3.1.

Note:

Latitude: 12°50'51.89"N; Longitude: 77°41'21.33"E 922 m above MSL;


- 31 -

Fig 3.2: Maps showing project boundary & project site location


- 32 -

3.3 BASIS OF SELECTING THE PROPOSED SITE

The efficient functioning of any industry mainly depends on the availability of its basic requirements viz. raw materials, fuel, power, water, manpower etc.

The industry is proposed to be established in KSSIDC Industrial esatate, Bangalore. The choice of the land confers several advantages, which are

summarized below.

1. The site is well connected by roadways. 2. Water will be supplied from Borewell. 3. Power will be supplied from BESCOM.

4. Housing colonies, educational facilities, hospitals and other amenities are expected to be developed due to proposed industrial area development.

5. No incidence of cyclones, earthquake, floods or landslides in the region.

3.3.1 Proposed environmental safeguards 1. What type of mitigative measures has been incorporated for

control & prevention of water pollution due to effluent discharge?

Industrial effluent is proposed to be treated in Common effluent Treatment Plant with Multiple Effective Evaporator followed by RO Filtration for treatment, reuse and disposal.

The domestic sewage will be treated in septic tank and disposed to soak pit.

Adequate measures are adopted for collection and storage of effluents generated in the Industry and also to prevent spillages and

overflows. Therefore pollution in the surrounding areas is not anticipated.

2. Measures incorporated for control & prevention of air pollution due to boiler stack, DG exhaust and process exhaust?

1) Well-designed stacks of adequate heights are proposed for the

boiler and diesel generator for dispersion of gaseous emissions at levels as per the guidelines.

2) Well designed scrubbers (column – 1 no) will be proposed for scrubbing the fumes emanating from the process area so that the neutralized fumes are let out into the atmosphere at a height so as

to not affect GLC’s (ground level concentraction).


- 33 -

3. Measures proposed for prevention of adverse effect on fragile ecosystem?

The proposed APIs, Intermediates manufacturing industry is coming up in a designated industrial area & and it is not an ecologically

sensitive area. Therefore no adverse effects on the fragile ecosystem are anticipated.

3.4 SIZE/MAGNITUDE OF OPERATION The industry “M/s. Somu Chemicals & Pharmaceutical Pvt. Ltd.,” is a small

scale industrial unit with a total capital investment of Three Crores Forty Two Lakhs only. The total production capacity proposed is 65 MT/Annum.

3.5 MANUFACTURING PROCESS DESCRIPTION

3.5.1 Products manufactured

The following APIs and Intermediates are proposed to be manufactured.

Table 3.1: APIs and Intermediates are proposed to be manufactured

Sl. No.


(kg/month)

Production capacity

(kg/annum)

A Herbal extract

1 Coleus Forskholii Extract

500 6000

2 Curcumin 250 3000

3 Tetrahydrocurcuminoids 250 3000

4 Piperine 83 1000

5 Tetrahydropiperine 83 1000

Total 1,166 14,000---A


1 Benzalkonium chloride 333 4000

2 4-n Hexylresorcinol 250 3000

3 4-n Butylresorcinol 167 2000

4 2-Methylresorcinol 83 1000

5 1,4-Cyclohexanedione 500 6000

6 Tamsulosin HCl and its Intermediates

83 1000

7 1-Chloromethyl Naphthalene

833.33 10000

8 Piroctone Olamine 1000 12000

9 Ethylhexyl Trizone 500 6000


- 34 -

10 Benzathonium chloride 167 2000

11 Iscotrizinol 167 2000

12 Tinosorb S 83.33 1000

13 Tinosorb M 83.33 1000

Total 4250.98 51000---B

Grand total (a+b) 65,000

Note:

The total production capacity is 65,000 kg/annum.

3.5.2: Manufacturing process description: The manufacturing process for each product proposed to be produced is described with stoichiometric and gravimetric balances along with process

description and material balance flow charts as under.

Herbal extract Products:

3.5.2.1 Coleus Forskholli Extract

CAS NO : 66575-29-9

Mol.Formula : C22H34O7

Mol.Wt : 410.5

IUPAC Name : R,4aR,5S,6S,6aS,10S,10aR,10bS)-6,10,10b-trihydroxy-3,4a,

7,7,10a-pentamethyl-1-oxo-3-vinyldodecahydro-1H-benzo[f]chromen-5-yl

acetate.

Structure:

http://upload.wikimedia.org/wikipedia/commons/e/ed/Forskolin.png


- 35 -

Brief Process:

Coleus Oleoresin dissolved in 4.5 volume of Toluene and stirred

for 2 hrs at 25 -30 deg C and the Dissolved material is precipitated by

adding Hexane. The precipitated material filtered and dried under vacuum at

45 – 50 deg C .The final material analysed by HPLC and further diluted with

Dextrin.

Application:

Used for lean body mass and in cosmetics as a skin conditioning agent .

Raw Material Consumption and Material Balance 50 Kg final product

SL.NO. Raw Materials

Qty Input in Kgs.

Qty.Out put in Kgs

Loss Kg of RM / Kg of Final Product.

1 Coleus Roots Powder

1000.Kg

1200 Kg (Spent powder

Contains water) Used for

Brickets for Steam boilers

50 Kg

Coleus oil 1% Product

( for reuse )

-

2

Toluene

3000 Ltr

2910 Ltr ( for reuse )

90 Lts

3 Hexane 300 Ltr 285 Ltr ( for reuse)

15 Ltr

4 Dextrin 25.0Kg - -


- 36 -

Process Flow Chart:

Coleus Hexane

Oleoresin Toluene

Concentration

Dextrin

Filtration

MLR Wet Product

Residue Oil Drying Under

Vacuum

Milling

Shifting

Blending

Packing


- 37 -

3.5.2.2 CURCUMIN:

CAS NO : 458-37-7


Mol.Wt : 368.38

IUPAC Name : (1E, 6E)-1,7-bis (4-hydroxy- 3-methoxyphenyl) -1,6-

heptadiene-3,5-dione

Structure :

Brief Process:

Vanillin condensed with acetylacetone in the presence of base Tri secondary

butyl borane by using ethylene chloride as a solvent gives to crude curcumin

further it is washed with water followed by Isopropyl alcohol.

Filtered the Product and dried under Vacuum at 45-50 deg C till LOD reaches

Less than 0.5% then packed in Clean Polythene Bag.

http://upload.wikimedia.org/wikipedia/commons/1/1f/Curcumin-enol.png


- 38 -

Raw Material Consumption and Material Balance 100 Kg of Final Product

Sl.NO.

Raw Materials

Qty Input in Kgs.

Qty.Output in Kgs

Loss In Kgs/Ltr

Kg of Raw

Materials / Kg of Final Product.

1 Vanillin 111.Kg 0 0 1.111

2 Acetyl acetone 37.Kg 0 0 0.366

3 Boric oxide 18.Kg 0 0 0.177

4 TSBB 205.Kg 0 0 2.05

5 n-Butylamine 9.Kg 0 0 0.088

6 Ethylacetate 675.ltr 645.ltr (for re-use)

30 Ltr

7.98

7 Water for process

1675.ltr 1675.ltr ( Inorganic

Waste)

(for CETP)

0

16.66

8 Water for

reactor washing

500.ltr 500.ltr

Organic waste

(for CETP)

0

5.55


- 39 -

Process Flow Sheet: Curcumin

Acetic acid Ethylene dichloride

Acetyl acetone water

Vanillin TSBB

Water SS Nutsche filter

IPA

Layer separation Filtration

SS SSMultimill

SS Vacuum Tray drier

SS Shifter

SSR- 1.KL Filtration

MLR Wet Product

Drying

U /Vacuum Milling

Shifting

PACKING

Water for

CETP

EDC

For recovery and re use

Wet Product IPA

for recovery and

reuse


- 40 -

3.5.2.3 TETRAHYDRO CURCUMINOIDS:

CAS NO : 36062-04-1


Mol.Wt : 372.2

IUPAC Name : (1,7-Bis (4-hydroxy-3-methoxyphenyl) heptane-3,5-dione

Structure :

Brief Process:

Curcuminoids obtained from Turmeric is hydrogenated by using Palladium on

Carbon as a Catalyst gives to TetrahydroCurcuminoids.



Application:

Used as an skin conditioning and skin whitening agent.


- 41 -

Raw Material Consumption and Material Balance: 100 Kg Out put Final Product

Sl.NO.

Raw Materials

Qty.Input in Kgs.

Qty.Output in Kgs

Loss

Kg of RM

input / Kg of Final out put

1 Curcuminoids 166.Kg 0 0 1.428

2 Acetone 1660.Ltr 1580.Ltr ( for re-use)

80 Ltr

11.22

3 Palladium

Carbon

8.Kg 8.Kg

(for regeneration)

0

0.177

4 IPA 500.ltr 475.ltr (for re-use)

25 Ltr

2.05

5 H2 Cylinder 3.Nos 0 0 0.088

6 N2 Cylinders 1.Nos 1 No 1 No

7 Water for

reactor washing

500.ltr 500.ltr

(Inorganic) (For CETP)

0 5.55


- 42 -

Process Flow Sheet: Tetrahydrocurcuminoids

Acetone

Pd on C

Curcuminoids H2

N2

SS Pressure filter

Concentration U/Vacuum

SSR 1.KL

IPA

SS Nutsche filter

Filtration

SS Vacuum Tray Drier

SS Multi mill

SS Shifter

Hydrogenator

SS -1.KL

Filtration

Palladium on Carbon

for regeneration

Residue

Drying

U /Vacuum

Milling

Shifting

Packing

Wet Product IPA

for recovery and

re use


- 43 -

3.5.2.4 PIPERINE

CAS NO : 94-62-6

Mol.Formula : C17H19NO3

Mol.Wt : 285.34

IUPAC Name :1-[5-(1,3-benzodioxol5-yl)-1-oxo-2,4-pentadienyl]piperidine

Structure :

Brief Process:

Crotyl bromide condensed with Phosphorane gives to Crotyl phosphorane

derivative which is condensed with Piperonal in th presence ot sodium

methoxide gives to Methyl Piperate. Methyl Piperate finally condensed with

Piperidine in the presence of Sodium methoxide in methanol gives to Piperine..



Application:

Used as an enhancers of nutrient and bio availability enhancer for medicines.


- 44 -

Raw Material Consumption and Material Balance 80 Kg Final product

Sl.NO.

Raw Materials in Kgs.

Qty Used/batch

in Kgs.

Qty.Out put/Batch

in Kgs

Kg of Raw

Materials / Kg of Final Product.

1 Methyl Bromocrotonate

100.Kg - 1.25

2 Triethyl Phosphite 95.Kg - 1.18

3 Piperidine 65.Kg 0.81

4 DMF 300.ltr - 3.54

5 Sodium Methoxide 10.Kg - 0.125

6 Methanol

500.ltr

450.ltr

(for re-use)

4.94

7 Water for Process 700.ltr 700.ltr (for CETP)

8.75

8 Water for reactor washing

500.ltr 500.ltr (For CETP)

6.25


- 45 -

Process Flow Sheet: Piperine.

Methyl Bromocrotonate

Triethyl phosphite DMF

Sodium Methoxide

Water

Filtration SS Centrifuge


SS Multi mill

SSR-1.KL

Drying

U /Vacuum

Milling

Wet Product

Aquous DMF

For recovery and

Re use

SSR-1.KL


- 46 -

Methanol

Piperidine Sodium Methoxide

Chilled Water

Filteration SS Nutsche filter


SS Multi mill

SS Shifter

Shifting

Packing

SSR-1.KL

Aquous Methanol

for recovery and

re use

Wet Product

Drying

U /Vacuum

Milling


- 47 -

3.5.2.5 Tetrahydro Piperine:

CAS NO : 23434-88-0

Mol.Formula : C17H23NO3

Mol.Wt : 289.36

IUPAC Name : 1- [5- (1, 3-Benzodioxol-5 yl)-1-oxo-pentanoyl]-Piperidine

Structure :

Brief Process:

Piperine obtained from Pepper is hydrogenated by using Palladium on Carbon

as a Catalyst gives to Tetrahydropiperine.



Application:

Used as an enhancers of nutrient and bio availability enhancer for medicines.


- 48 -


Sl.NO.

Raw Materials

Qty Input in Kgs.

Qty.Out put in Kgs

Loss

Kg of RM

input / Kg of Final Output

1 Piperine 71.Kg 0 1.428

2 Acetone 710.Ltr 675.Ltr ( for re-use)

35 Ltr

11.22

3 Palladium

Carbon

3.5Kg 3.5Kg

(for re-use)

0 Kg

0.177

4 IPA 215.ltr 205 ltr

(for re-use)

10 Ltr 2.05

5 H2 Cylinder 2.Nos 0 0 -

6 N2 Cylinder 1 No 0 1 No

8 Water for

reactor washing

300.ltr 300.ltr

Organic waste (For CETP)

0 Ltr

5.55


- 49 -

Process Flow Sheet: TetrahydroPiperine

Acetone

Pd on C

Piperine H2

N2

SS Pressure filter


SSR -1.KL

IPA

SSR-1.KL

Filtration

SS Vacuum Tray drier

SS Multimill

SS Shifter

Hydrogenator

SS-1.KL

Filtration

Palladium on Carbon

for regeneration

Residue

Drying

U /Vacuum

Milling

Shifting

Packing

Wet Product IPA

For recovery and

Re use


- 50 -

3.5.3 Cosmetics ingredients, neutraceutical ingredients,

pharama intermediates and API

3.5.3.1: BENZALKONIUM CHLORIDE

CAS NO. : 8001-54-5

MOl.Formula : [C6H5CH2N(CH3)2R]Cl Mol.Wt. : C10,C12,C14 and C16 Homolog’s are 312,340,368,and 396

IUPAC Name : Alky lbenzyldimethylammonium chloride

INTRODUCTION:

Quaternary compounds, including the benzalkonium salts, constitute an

economically important class of industrial chemicals that are widely distributed

among a diverse array of products and users from an industrial to the

household sector. Because of their strong cationic surface activity, quaternary

compounds are used primarily as disinfectants biocides, and detergents, but

also as anti-elecectrostatics and as phase transfer catalysts

Very important features of benzalkonium salts are their bactericidal and

antimicrobial properties.The antimicrobial activity depends on a changing

length of the side n-Alkyl chain. It is well known that the C12-homologue is

most effective against yeast and fungi, the C-14-homologue against gram-

positive bacteria and C16-homologue against gram-negative bacteria. Widely

used as preservatives for ophthalmic, nasal and parenteral products. They are

also used as topical antiseptics and disinfectants for medical equipments.

These compounds are not generally used as single componenets, but

rather as mixtures as composed of two or thress benzlkonium members


- 51 -

differing only in the length of the alkyl chains. Such mixtures are produced on

a large –scale in industry. Howvever, a targeted synthesis of pure individuals

could be of interest because of the above-mentioned specicity of each salt

against different pathogens.

PreparatIon of the compounds has been compounds has been described

previously, but a general synthesis applicable to the whole series of

benzalkonium slats is advanced in method.

The N-benzyl-N,N-dimethylalkyl chlorides were prepared by the general

method shown below.

BRIEF PROCESS:

N, N-Dimethyl Alkylamine charged into the reactor. DM Water charged in to the

reactor under stirring at room temperature. Benzyl chloride slowly added in to

the reactor under stirring over a period of 2 -3 hrs. The temperature of the

reaction mass maintained at 50 -60 deg C during the addition of benzyl

chloride.The Reaction mass stirring maintained for extra hours for complete

conversion of the reaction. Finally sample send to QC for analysis of pH and

Active matter.

Raw Material Consumption and Material Balance

1000 Kg out put of Final Product

Sl.NO.

Raw Materials

Qty Input in Kgs.

Qty.Out put in Kgs

Loss

Kg of RM /

Kg of Final Product.

1 Amine 340.Kg - - 0.3401

2 DM Water 456.Kg - - 0.2882

3 Benzyl chloride

204.Kg - -

0.47755

7 Water for process

- - - -

8 Water for reactor

washing

500.ltr 500 .ltr Organic

(for CETP)

-

0.3401


- 52 -

Process Flow Chart:

Sample to QC - Inprocess Check pH &TAV Rxn Temp: 50-80 deg C Cool to 25 – 30 Deg C Sample to QC for Clarity Sample to QC –Complete Analysis

Critical Process Parameters:

1. Addition of Benzyl Chloride at 50 – 60 deg C

2. The Reaction mass stirring maintained for extra hours for complete

conversion of the reaction

3. Micron filtration for Clarification.

ALKYLAMINE

DM WATER

REACTOR

BENZYL

CHLORIDE

UNLOADED IN TO

THE CONTAINERS

MICRON

FILTERATION


- 53 -

3.5.3.2 4-N HEXYL RESORCINOL

CAS NO : 136-77-6

Mol. Formula : C12H18O2

Mol. Wt : 194.27

IUPAC Name : 4-Hexyl-1,3-benzene diol,1,3-dihydroxy phenyl hexane.

Structure:

Brief Process:

Resorcinol condensed with Caproic acid in the presence of zinc catalyst gives

to 4-hexanoyl resorcinol. Hydrogenation of hexanoyl resorcinol in the presence

of Raney Nickel gives to 4-N Hexyl Resorcinol.

Application :

Used as a skin whitening agent in cosmetics and also as a anti-dandruff agent

in shampoo .


- 54 -

Raw Material Consumption and Material Balance 50 Kg Out put Final product

Sl.NO. Raw Materials

Qty

Input in Kgs.

Qty.Output

in Kgs

Loss Kg of RM

input / Kg of Final Output.

1 Resorcinol 100.Kg 0 2.00

2 Caproic acid 200.Kg 0 4.00

3 Zinc catalyst 10.Kg 10 Kg Inorganic

(For CETP)

0.2

4 Raney Nickel 10.Kg 10.Kg

(for regeneration

& re-use)

0.2

5 Methanol

500.ltr

475.ltr

(for re-use)

7.91

6 Hexane

500.ltr

475. ltr (for re-use)

6.5


N2 Cylinders 1 No 1 No 1 No

8 Water for

Process

600.ltr 600.ltr

(Inorganic) (for CETP)

0

12

9 Water for

reactor washing

500.ltr 500.ltr

(Organic) (For CETP)

0 10


- 55 -

Process Flow Sheet: 4-N Hexyl Resorcinol

Caproic acid

Zinc catalyst.

Resorcinol

Water

SSR-0.5 KL

SSR 0.5KL

High Vacuum Distillation

H2

Methanol N2

Raney Nickel

Hexane


SSR .0.5 KL

SSR-0.5 KL Layer

Separation

Water Layer

for CETP

Organic layer

Residue

Residue

Hydrogenator

SS -1 KL

Raney Nickel Spent

Regeneration and

Reuse

Wet Solids Hexane for

Recovery

and reuse


- 56 -


SS Multimill

SS Shifter

Milling

Blending

Packing

Drying

U/Vacuum

Drying

U/Vacuum

U/Vacuum

Shifting


- 57 -

3.5.3.3: 4-n butyl resorcinol

CAS NO : 18979-61-8

Mol. Formula : C10H14O2

Mol. Wt : 166.22

IUPAC Name : 4-Butyl-1,3-benzene diol,3,4-dihydroxy-N-Butyl benzene

Structure :

Brief Process:

Resorcinol condensed with butyric acid in the presence of zinc catalyst gives

to 4-butyroyl resorcinol. Hydrogenation of butyroyl resorcinol in the presence of

Raney Nickel gives to 4-N Butyl Resorcinol.

Application :

Used as a skin whitening agent in cosmetics and also as a anti-dandruff agent

in shampoo.


- 58 -

Raw Material Consumption and Material Balance 50 Kg out put of Final Product

Sl.NO.

Raw Materials

Qty Input in Kgs.

Qty.Out put in Kgs

Loss

Kg of RM

input / Kg of Final Product.

1 Resorcinol 111.Kg - 2.22

2 Butyric acid 194.Kg - 3.88

3 Zinc catalyst 11.1.Kg 11.1 Kg Inorganic

For CETP

0.22

4 Raney Nickel 11.1.Kg 10.Kg

(for regeneration

& re-use)

0.22

5 Methanol

555.ltr

530.ltr

(for re-use)

25 Lts 8.788

6 Hexane

555.ltr

525ltr (for re-use)

30 Lts 7.26


N2 Cylinder 1 No 1 No 1 No

8 Water for Process

600.ltr 600.ltr Inorganic

(for CETP)

0

13.33

9 Water for

reactor washing

500.ltr 500.ltr

Organic (For CETP)

0 11.11


- 59 -

Process Flow Sheet: 4-N Butyl Resorcinol

Butyric acid

Zinc catalyst.

Resorcinol

Water

GLR-1.KL

High Vacuum Distillation

SSR-1.KL

H2

Methanol N2

Raney Nickel

Hexane


SSR – 1.KL

GLR-1.KL Layer

Separation

Water Layer

for CETP

Organic layer

Residue

Residue

Hydrogenato

SS.1 KL

Raney Nickel Spent

Regeneration and

Re use

Wet Solids Hexane for

Recovery

and re use


- 60 -


SS Multi mill

SS Shifter

Milling

Blending

Packing

Drying

U/Vacuum

Shifting


- 61 -

3.5.3.4: 2 Methyl Resorcinol

CAS NO. : 637-88-7

MOl.Formula : C6H8O2 Mol.Wt. : 124.14

IUPAC Name : Resorcinol-2-Methyl, 2-Methyl-1,3-Dihydroxy Benzene

Structure :

Brief process : Condensation of 1,3-CHD with aquous formaldehyde in the presence of

dimethylamine in methanol followed by 5% pd/c reduction and neutralization

with hydrochloric acid Results in 2-Methy-1,3-cyclohexanedione .

The above obtained 2-Methyl-1,3-Cyclohexanedione undergoes

dehydrogenation by using mesitylene as a solvent to get 2-Methylresorcinol.


- 62 -

Raw Material Consumption and Material Balance 100 Kg out put of final Product

Sl.NO.

Raw Materials

Qty Input

in Kgs.

Qty.Out put

in Kgs

Loss

Kg of RM input / Kg

of Final Product.

1 1,3-Cyclohexanedione

158.Kg - - 1.5873

2 Dimethylamine 158.Kg - - 1.5873

3 Formaldehyde 150.Kg - - 1.507

4 Palladium on Carbon 5%

48.Kg 48.Kg (For re-use)

-

0.0476

5 Hydrochloric acid 121.Kg - - 0.1587

6 Mesitylene 1425.ltr 1355.ltr

(for re-use)

70 Ltr

0.1587

7 Water for process

600.ltr 600.ltr Organic

salts (for CETP)

- 9.5238



(for CETP)

- 7.9365


- 63 -

Process Flow Chart:

Formaldehyde

Methanol

1, 3-CHD

DMA

Pd/C Catalyst

Spent Catalyst

DM Water Recovered Aquous methanol

HCl

MLR

SSR

Reduction

Filteration

Clear filtrate

Distillation

U/Vacuum

Filteration

Drying

U/Vacuum


- 64 -

Pd/C

Mesitylene

MLR

QC

Shifting

Milling

Packing

Dehydrogenation

Filteration

Drying

U/Vacuum


- 65 -

3.5.3.5: 1, 4- Cyclohexanedione

CAS NO. : 637-88-7

MOl.Formula : C6H8O2

Mol.Wt. : 112.12

IUPAC Name : 1, 4-Cyclohexanedione, Cyclohexane-1,4-dione

Structure :

BRIEF PROCESS :

Condensation of DMS in presence of Sodium methoxide followed

by neutralization with Aquous sulphuric acid gives to Dicarbmethoxy carboxy -

1,4-CHD . Decarboxylation of Dicarbmethoxy carboxy -1,4-CHD results in

Cyclohexane-1,4-dione.


Sl.NO.

Raw Materials in

Kgs.

Qty.Input/

Batch in Kgs.

Qty.Out

put/Batch in Kgs

Loss

Kg of Raw Materials

/ Kg of Final

Product.

1 Dimethyl Succinate 333 Kg 0 0 3.333

2 Sodium Methoxide 187 Kg 0 0 1.867

3 Methanol 720 Ltr 684 Ltr

(For re-use)

36 Ltr

3.333

4

Con .Sulphuric acid

170 Kg 0 0 1.70

5

Ethyl acetate 1670 Ltr 1590. Ltr (For re-use)

80 Ltr

1.667

6

Charcoal 13 Kg 13 Kg (Soild waste)

0 0.333

7

Water for process

1200.ltr

1188.ltr (Inorganic

for CETP)

12 Ltr

30

8


600.ltr

600.ltr

(Organic for CETP)

0

16.667


- 66 -

FLOW CHART:

Methanol

Sodium Methoxide

DMS

Aquous Sulphuric acid

MLR

DM Water

Ethyl acetate

Activated Carbon

SSR

Neutralisation

Filteration

Tray Drying

Pressure Reactor

Distillation

U/Vacuum

Filteration

Distillation

Water

Spent carbon

Recovered Ethyl acetate


- 67 -

MLR

Filteration

Drying

U/Vacuum

Milling

Packing QC


- 68 -

3.5.3.6 TAMSULIN HCL

PRODUCT : Tamsulosin HCl

CAS NO. : 106463-17-6

MOl.Formula : C20 H28 N2 O5 S.HCl Mol.Wt. : 444.97

IUPAC Name :(-)-[R]-5-[2-[[2-(o-Ethoxyphenoxy)ethyl]amino]propyl]-2- methoxybenzenesulfonamide

monohydrochloride

Structure :

BRIEF PROCESS :

Condensation of 5(2-Amino-Propyl)2-Methoxy-Benzene-Sulphonamide (MBS) with 2-(O-ethoxy-Phenoxy) ethyl bromide (EEB ) in

presence of Sodium carbonate in Isopropyl alcohol followed by recrystallisation from ethyl acetate gives to Tamsulosin base. Tamsulosin base acidified with hydrochloric acid in

methanol followed by charcoalisation ,filtration and chilling results in Tamsulosin HCl.


- 69 -

Raw Material Consumption and Material Balance 25 Kg out put of final product

Sl.NO.

Raw Materials

Qty.Input in Kgs.

Qty.Out in Kgs

Loss

Kg of RM

/ Kg of Final

Product.

1 5(2-Amino-Propyl)2-

Methoxy-Benzene-

Sulphonamide

27.5 Kg 0 0 3.333

2 2-(O-ethoxy-Phenoxy) ethyl

bromide

25.0 Kg 0 0 1.867

4

Sodium

Carbonate

17.0 Kg 0 0 1.70

5

Isopropyl

alcohol

125.0 Ltr 119. Ltr

(For re-use)

6.0Ltr

1.667

Ethyl acetate 175.0 Ltr 167.0ltr 8.0 Ltr

Methanol 140.0 ltr 133.0 ltr 7.0 ltr

6 Charcoal 0.5 Kg 0.5Kg (Soild waste)

0 0.333

Con Hcl 7.5 ltr 0 0

7 Water for

process

70.ltr 70.ltr

(Inorganic for CETP)

0 30

8


100 100.ltr (Organic for

CETP)

0

16.667


- 70 -

FLOW CHART:

SSR

Isopropyl alcohol Sodium Carbonate MBS EEB

DM Water

Ethyl Acetate Recovered IPA for reuse

Ethyl acetate MLR for Recovery –reuse

CETP organic solid waste

SSR

Methanol

Charcoal

Condensation

Filtration

Distillation

Neutralization

Organic Layer

Ethyl Acetate layer

RT Stirring

Aquous Layer

(Inorganic) For CETP

Wet Cake

Charcoalisation


- 71 -

Con HCl

Wet Cake

Shifting

Drying

U/Vacuum

Packing

Organic Layer

Methanol Solution

Stirring /Chilling

Spent Charcoal


Filtration

Filtration

MLR for Recovery

Organic solid waste CETP

Sample for QC for Complete Analysis.


- 72 -

3.5.3.7 1-Chloromethyl Npthalene

PRODUCT : 1-(Chloromethyl)naphthalene

CAS NO. : 86-52-2

MOl.Formula : C11H9Cl Mol.Wt. : 176.65 g/mol

IUPAC Name : 1-Naphtylmethyl chloride.

Structure :

BRIEF PROCESS :

Chloromethylation of Naphthalene by using para-formaldehyde and con.hydrochloric acid.

In the presence of ortho-phosphoric acid by using glacial acetic acid as a solvent gives to crude 1-(Chloromethyl) naphthalene . High Vacuum

distillation of 1-(Chloromethyl) naphthalene gives to Pure 1-(Chloromethyl) naphthalene.


- 73 -


200 Kg final product

Sl.NO.

Raw Materials

Qty.Input

in Kgs.

Qty.Out put

in Kgs

Loss

Kg of RM / Kg of Final

Product.

1 Naphthalene 278.0 Kg 0 0 3.333

2 Para-Formaldehyde

100.0 Kg 0 0 1.867

3 Glacial Acetic acid

290.0 Ltr 0 0

3.333

4 Con .HCl 335 Ltr 0 0 1.70

5

Ortho-

Phosphoric acid

160 Ltr 0

0

1.667

6 Water for process

2000.ltr 2000 ltr +

290 Ltr Acetic acid

(Inorganic for CETP)

0

30

7


500.ltr 500.ltr (Organic for

CETP)

0

16.667

FLOW CHART:

GLR

Naphthalene

Para-formaldehyde

Con.HCl

Ortho-phosphoric acid

Chloromethylation

Organic Layer

Aquous.Hydrochloric acid

For CETP


- 74 -

Organic Layer

Nutralisation

Organic Layer

Distillation U/Vac

Organic Layer

Organic Layer

Main Fraction

Packing

DM Water Aquous layer Inorganic

for CETP

Aquous layer Inorganic

for CETP

DM Water

Aquous layer Inorganic

for CETP

Distilled EDC for reuse

Sample to QC fro

complete Analysis

EDC

Sodium Bicarbonate

Solution


- 75 -

3.5.3.8 Piroctone Olamine:

PRODUCT : Piroctone Olamine

CAS NO. : 68890-66-4 MOl.Formula : C14H23NO2 · C2H7NO Mol.Wt. : 298.42 g/mol

IUPAC Name : 1-Hydroxy-4-methyl-6-(2,4,4-trimethylpentyl)pyridin-

2(1H)-one compound with 2-aminoethanol (1:1) Structure :

BRIEF PROCESS :

Esterification of 3,3’DMAA with Methanol in the presence of con

Sulphuric acid gives to Methyl ester of 3,3’DMAA Further condensation of methyl ester of 3.3’DMAA with Isononanoyl chloride catalysed by Anhydrous Aluminium Chloride gives to Isononayl derivatives of 3,3’ DMAA.

Isononanyl derivative of 3,3’ DMAA undergoes cyclisation in the presence

of Sodium methoxide in methanol at 5 – 10 Deg C followed by neutralization

with acetic acid gives to Crude 4-Methyl-6-(2,4,4-trimetylpentyl)-2-Pyrone. Further 4-Methyl-6-(2,4,4-trimetylpentyl)-2-Pyrone

Is purified by High Vacuum distillation. The above purified 4-Methyl-6-(2,4,4-trimethylpentyl)-2-pyrone condensed

with hydroxylamine hydrochloride in the presence of sodium Carbonate at 60 – 65 ˚C gives to 1-Hydroxy-4-Methyl-6-(2,4,4-trimethylpentyl)-2-pyridone further treated with monoethanolamineUnder chilled condition 8 – 10 ˚C results in

formation of Crude Piroctone olamine.

The above obtained crude product is recrystallised from ethyl acetate.


- 76 -


Sl.NO.

Raw Materials

Qty.Input

in Kgs.

Qty.Out put

in Kgs

Loss

Kg of RMs / Kg of

Final Product.

1 3,3'-DMAA 125.0Kg 0 0 100

2 Isononanoyl chloride

250.0 Kg 0 0 1.867

3 Anhyd.Aluminium Chloride

500.0 Kg 0 0 3.333

4 Sodium methoxide 125.0 Kg 0 0 1.70

5 Monoethanolamine 12.5 Kg 0 0 1.667

6 Hydroquinone 12.5 Kg 0 0 0.333

7 Sodium Carbonate 125.0 Kg 0 0

8 Glacial Acetic acid 125.0 Kg 0 0

9 Methanol 750.0 Ltr 713 Ltr 37 Ltr

10 Hydroxylamine Hcl 190 Kg 0 0

12 Con . Sulphuric

acid

25.0 Kg 0 0

13 Ethyl Acetate 1250.0 Ltr 1220 Ltr 60 Ltr

14 EDC 750 Ltr 715 Ltr 35 Ltr

15 Water for process 1500.ltr 1500.ltr (Inorganic

for CETP)

30

16

Water for reactor

washing

750.ltr 750.ltr

(Organic for CETP)

0

16.667


- 77 -

Process Flow chart:

GLR

3, 3’DMAA Methanol Con.H2SO4 Hydroquinone

GLR

EDC

DM Water Aquous Layer

Inorganic forCETP

GLR

Sodium Bicarbonate Soln. Aquous layer

Inorganic for CETP

SSR

Distilled EDC for reuse

Sample to QC for MC

Anhyd.Aluminium Chloride GLR

Isononanoyl chloride Water washings for

DM Water + Con HCl Inorganic

for CETP

Sodium Bicarbonate Soln. SSR

Recovered EDC for reuse

Sample to IPQC

Esterification

Layer

Separation

Organic Layer

Nutralisation

Organic Layer

EDC Layer

Distillation U/Vac

Organic Layer

EDC Layer

Reaction and

Nutralisation

Organic Layer

EDC Layer

Distillation U/Vac

Concentrate


- 78 -

SSR

Residue Solid waste

Organic for CETP

SSR

SSR Sodium Carbonate Hydroxylamine HCl

Ethyl acetate

DM Water

SSR

Recovered Ethyl acetate

MEA at 50 -55˚C For reuse

Chilling 5 -10 ˚C

Wet Cake

Filtration

MLR for Recovery


Concentrate

High Vacuum

Distillation

Pure Product.

Reaction

Organic Layer

Ethyl acetate

Spent Charcoal


Distillation


- 79 -

Ethyl acetate

Chilling 5-10˚C

Sample to QC for Complete Analysis.

Shifting

Drying

U/Vacuum

Packing

Recrystallisation

Filtration

MLR for Recovery


Wet Cake


- 80 -

3.5.3.9 Ethyl Trizone

PRODUCT : Ethylhexyl Triazone

CAS NO. : 88122-99-0

MOl.Formula : C48H66N6O6 Mol.Wt. : 823.07 g/mol

IUPAC Name : 2-ethylhexyl 4-[[4,6-bis[[4-(2-ethylhexoxycarbonyl)phenyl]amino]-1,3,5-triazin-2- yl]amino]benzoate

Structure :

BRIEF PROCESS :

PNBA (P-Nitrobenzoic acid) is esterified with 2-Ethylhexanol in presence of catalytic quantity of Sulfuric acid to get PN2EHB (Para nitro 2-ethyl hexyl

benzoate). The Sulfuric acid is neutralized with Soda ash and the Unreacted PNBA is extracted with aqueous Soda ash solution which on neutralization gives recovery PNBA.

PN2HB is reduced to PA2EHB (Para amino 2-ethyl hexyl benzoate) in presence of Pd/C-H2 in methanol. Pd/C is filtered and reused. Methanol

distilled and sent for column distillation. To the residue Hexane is added to expel the product and centrifuged. PA2EHB is reacted with Cyanuric chloride in Xylene to get Etone.

To the reaction mass water is added and PH is adjusted with ammonia. Aqueous layer seperated and sent for evaporation. The Xylene layer taken for Xylene distillation (recovery). To residue Acetonitrile is added and charcolised –

cooled and filtered.


- 81 -


Sl.NO.

Raw Materials

Qty Input

in Kgs.

Qty.Output

in Kgs

Loss

In Kgs/Ltr

Kg of Raw Materials /


1 2-Ethylhexanol 85 Kg 0 0 0.85

2 Acetonitrile 610. Ltr 580 Ltr 20 Ltr 6.10

3 Ammonia 25% Solution

6.Kg 0 0 0.06

4 Cyanuric chloride 25.Kg 0 0 0.25

5 P-nitro benzoic

acid

30.Kg 0 0 0.30

6 Sodium chloride 6.Kg 6.Kg in

water

0

0.06

7 Methanol 710 Ltr 675 Ltr 35 Ltr 7.10

8 Hexane 570 Ltr 540 Ltr 30 Ltr 5.70

9 Sodium Carbonate

6 0 0 0.06

10 PD/C 10% 5 Kg 5 Kg 0 0.05

11 Perchloroethylene 945 Lt 890 55 Ltr 9.45

12 Carbon 5 Kg 5 0 0.05

13 Sulphuric acid 5.5 Kg 0 0 0.055

14 Xylene 400 Lt 380 Lt 20 Ltr 4.00

15 Water for process


Waste)

(for CETP)

0

16.75

16


500.ltr

500.ltr Organic

waste

(for CETP)

0

5.00


- 82 -

RAW MATERIALS FLOW CHART: GLR

P-Nitrobenzoic acid 2-Ethylhexanol Perchloroethylene Sulfuric acid

GLR

Perchloro ethylene

DM Water Aquous Layer

Inorganic forCETP

GLR

Sodium Bicarbonate Soln. Aquous layer

Inorganic for CETP

SSR

Distilled PCE for reuse

Sample to QC for MC

Palladium on Carbon Hydrogenator

Methanol N2 gas

H2 gas

N2 gas

SSR

Recovered MeoH for reuse

Sample to IPQC

Esterification

Layer

Separation

Organic Layer

Nutralisation

Organic Layer

Distillation U/Vac

Hydrogenation

Clear filtrate

Distillation U/Vac

Concentrate

Reaction


- 83 -

Xylene

Cyanuric Chloride Ammonia (25%) Sol.

Activated Carbon

Acetonitrile

Sample to QC for complete analysis

Wet Cake

Shifting

Drying

U/Vacuum

Packing

Filtration

MLR for Recovery


Purification


- 84 -

3.5.3.10 Benzethonium Chloride:

PRODUCT : Benzethionium chloride

CAS NO. : 121-54-0 MOl.Formula : C27H42ClNO2 Mol.Wt. : 448.09 g/mol

IUPAC Name : N-Benzyl-N,N-dimethyl-2-{2-[4-

(2,4,4trimethylpentan-2- yl)phenoxy]ethoxy}ethanaminium chlorideStructure

BRIEF PROCESS :

Stage-1 : Diethylene Glycol reacts with Phosphorous Oxychloride in presence of

Sodium Hydroxide in aqueous

medium to get Stage-1 Compound.

Stage-2 : 4-Octyl Phenol on reaction with Stage-1 Compound in presence of

Sodium Hydroxide in Toluene solvent medium to form Stage-2 Intermediate.

Stage-3 : Stage-2 Intermediate reacts with Dimethylamine in presence of Ethyl

Acetate as solvent medium to give

Stage-3 Compound.

Stage-4 : Stage-3 Compound on reaction with Benzyl Chloride in presence of

Toluene as solvent medium and

gets purified with Carbon to obtain Benzethonium Chloride (BZC).


- 85 -


Sl.NO.

Raw Materials

Qty Input

in Kgs.

Qty.Output

in Kgs

Loss

In

Kgs/Ltr

Kg of Raw

Materials /

Kg of Final

Product.

1 2-Octyl Phenol 185.Kg 0 0 1.85

2 Benzyl chloride 100.Kg 0 0 1.00

3 Diethyleneglycol 106.Kg 0 0 1.06

4

Diethylamine (40%)

296.Kg 0 0 jn2.96

5 Ethyl acetate 1400 Ltr 1330 Ltr (for re-use)

70 Ltr (5%)

Vapour

loss

14

6 Phosphorous

oxy chloride

125.Kg 0 0

1.25

7 Sodium

hydroxide

155 Kg 0 0 1.55

8 Toluene 2670 Ltr 2615 Ltr

(For re-use)

55 Ltr

(2%) Vapour

loss

26.7

9 Water for process


Waste) (for CETP)

0

16.00


500.ltr 500.ltr Organic waste

(for CETP)

0

5.0


- 86 -

FLOW CHART:

GLR Diethylene Glycol Phosphorous Oxychloride

Sodium Hydroxide Aquous HCl for CETP Water

GLR

4-Octyl phenol

Stage-1 N2 gas

Sodium hydroxide Toluene recovery

and reuse

Toluene

GLR

Dimethylamine Ethyl acetate recovery and

reuse

Ethyl acetate

Water

GLR

Toluene

recovery and reuse Toluene

Activated Carbon

Benzyl chloride

Sample to QC

Stage-1

Wet Cake

Shifting

Drying

U/Vacuum

Packing

MLR for Recovery


Stage-2

Stage-3

Stage-4


- 87 -

3.5.3.11 Isocotrizinol:

PRODUCT : Iscotrizinol

CAS NO. : 154702-15-5

MOl.Formula : C44H59N7O5

Mol.Wt. : 765.98 g/mol

IUPAC Name :Benzoicacid,4,4'-[[6-[[4-

[[(1,1dimethylethyl)amino]carbonyl]phenyl]amino]-1,3,5-triazine-2,4-

diyl]diimino]bis-,1,1'-bis(2-ethylhexyl) ester

Structure :

BRIEF PROCESS :

Stage-1 : p -Nitrobenzoic acid is reacted with Thionyl Chloride in the presence

of Dimethylformamide and

Toluene solvent media to get Stage-1 Compound.

Stage-2 : Stage-1 Compound on treatment with tert-Butylamine in presence of

Triethylamine using Toluene as solvent medium to form Stage-2 Intermediate.

Stage-3 : Stage-2 Intermediate on hydrogenation with Hydrogen in presence of

Palladium Carbon catalyst in Methanol and Toluene solvent media gives Stage-

3 Compound.


- 88 -

Stage-4 : Stage-3 Compound on reaction with Cyanuric Chloride in presence of

Potassium Carbonate using Acetonitrile as solvent medium to get Stage-4

Intermediate.

Stage-5 : Stage-4 Intermediate reacts with 2-Ethylhexyl 4-Aminobenzoate in

presence of Ammonia in Toluene and Hexane solvent media to obtain the title

compound.


100 Kg of Final Product

Sl.NO.

Raw Materials .

Qty Input

in Kgs.

Qty.Output

in Kgs

Loss

In Kgs/Ltr

Kg of Raw Materials

/ Kg of Final

Product.

1 2-Ethylhexyl 4-Aminobenzoate

100 Kg 0 0 1.00

2 Acetonitrile 255 Ltr 245 Ltr 10 Ltr 2.55

3 Ammonia 25%

Solution

41 Kg 0 0 0.41

4 Cyanuric chloride 45 Kg 0 0 0.45

5 Dimethylformamide 1 Kg 0 0 0.01

6 Hexane 540 Ltr 515 Ltr (Recovered-

reuse)

25 ltr(5%)

5.4


(Recovered-reuse)

20 Ltr 4.20

8 P-Nitro benzoic acid

48 Kg 0 0 4.80

9 Potassium Carbonate

19 Kg 0 0 0.19

11 Tert-Butylamine 29 kg 0 0 0.29

12 Carbon 1 Kg 1 kg (spent) 0 0.01

13 Toluene 1210 Ltr 1165 Ltr

(Recovered-reuse)

45

Ltr(4%)

12.10

14 Triethylamine 33 kg 0 0

0.33


- 89 -

15 Water for process 1500.ltr 1500.ltr

( Inorganic Waste)

(for CETP)

0

15.00

16

Water for reactor

washing

500.ltr

500.ltr Organic

waste (for CETP)

0

5.00

FLOW CHART:

GLR

P-Nitrobenzoyl chloride Toluene Tert-Butylamine Tri-ethylamine

GLR

Palladium on Carbon Hydrogenator

Methanol N2 gas

H2 gas

N2 gas

SSR

Cyanuric Chloride Recovered MeoH for reuse Acetonitrile

Potassium Carbonate

Water Sample to IPQC

2-Ethylhexyl 4-Aminobenzoate

Ammonia (25%) solution

Toluene

Hexane

Amination

Hydrogenation

Condensation

Condensation


- 90 -

Sample to QC for complete analysis

Wet Cake

Shifting

Drying

U/Vacuum

Packing

Filtration

MLR for Recovery

Organic solid waste

CETP


- 91 -

3.5.3.12 Tinsorb S:

PRODUCT : Tinosorb-S CAS NO. : 187393-00-6

MOl.Formula : C38H49N3O5 Mol.Wt. : 627.81 g/mol

IUPAC Name : Bis-ethylhexyloxyphenol methoxyphenyl triazine

BRIEF PROCESS : Stage-1 : 4-Bromoanisole is reacted with Magnesium metal in Tetrahydrofuran

medium to form Corresponding Grignard intermediate which is selectively reacted with Cyanuric Chloride to form Stage-1 Compound in Toluene medium, produt thus formed is isolated using Hexane and gets purified with Carbon.

Stage-2 : Stage-1 Compound is reacted with Resorcinol in presence of

Aluminium Chloride using Ethylene Dichloride and Isopropyl Alcohol as solvent media to get Stage-2 Intermediate.

Stage-3 : Stage-2 Intermediate reacts with 2-Ethylhexyl Bromide in presence of Sodium Carbonate using n-Butanol, Toluene and Dimethylformamide as

solvent media and gets purified with Carbon to obtain Tinosarb-S.


- 92 -


Sl.NO.

Raw Materials .

Qty Input

in Kgs.

Qty.Output

in Kgs

Loss

In Kgs/Ltr

Kg of Raw Materials /


1 2-Ethylhexyl Bromide

145 Kg 0 0 1.45

2 4-Bromoanisole 80 Kg 0 0 0.80

3 Aluminium Chloride

125 Kg 0 0 1.25

4 Cyanuric chloride 80 Kg 0 0 0.80

5 Dimethylformamide 590 Kg 0 0 5.90

6 Hexane 110 Ltr 105 Ltr (Recovered-

reuse)

5 ltr(5%)

1.10

7 Ethylene Dichloride 725 Ltr 690 Ltr

(Recovered-reuse)

36 Ltr(

5%)

7.25

8 Iodine 0.2 Kg 0 0 0.002

9 Isopropyl alcohol 1030 Ltr 975 Ltr (Recovered-

reuse)

55 Ltr(5%)

10.30

10 Magnesium 14 kg 0 0 0.14

11 n-Butanol 735 Ltr 700 Ltr 35 Ltr 7.35

12 Resorcinol 90 kg 0 0 0.90

13 Methanol 85 Ltr 80 Ltr (Recovered-

reuse)

5 Ltr 0.85

14 P-Nitro benzoic

acid

10 Kg 0 0 0.10

15 Sodium carbonate 150 Kg 0 0 1.50

16 Tetrahydrofuran 400 kg 380 kg 20 kg 4.00

17 Carbon 3Kg 3 kg (spent) 0 0.03

18 Toluene 1790 Ltr 1700 Ltr (Recovered-

reuse)

90 Ltr(4%)

17.90

19 Vitride (70%) in Toluene

0.4 kg 0 0

0.004

20 Water for process 1550.ltr 1550.ltr( Inorganic

Waste)(for CETP)

0

15.00

21 Water for reactor 500.ltr 500.ltr 0 5.00


- 93 -

washing Organic

waste (for CETP)

FLOW CHART:

4-Bromoanisole Tetrahydrofuran Magnesium Recovered Toluene for reuse Iodine Vitride (70%) in Toluenet Recovered Hexane for reuse Cyanuric Chloride Spent Carbon Toluene

Hexane Organic residue

Water

Stage-1 Ethylene Dichloride Recovered EDC for reuse Aluminium Chloride Resorcinol Recovered IPA for reuse Isopropyl Alcohol Water

Stage-2 Dimethylformamide Sodium Carbonate Recovered Toluene for reuse 2-Ethylhexyl Bromide Toluene Recovered n-Butanol for reuse Carbon Spent Carbon n-Butanol Water Organic residue for CETP

Stage-1

Stage-2

Stage-3


- 94 -

3.5.3.13 Tinsorb M:

PRODUCT : Tinosorb-M CAS NO. : 103597-45-1

MOl.Formula : C41H50N6O2

Mol.Wt. : 658.88 g/mol IUPAC Name : 2,2′-methanediylbis[6-(2H-benzotriazol-2-yl)-4-(2,4,4- trimethylpentan-2-yl)phenol]

BRIEF PROCESS :

Stage-1 : o -Nitroaniline is diazotized and coupled with 4-tert-Octylphenol in

presence of Sodium Nitrite, Sulfamic acid, Hydrochloric acid, SodiumHydroxide and Acetic acid using Methanol as solvent medium to form Stage-1 Compound.

Stage-2 : Stage-1 Compound in Toluene is further reacted with Zinc in

presence of Hydrochloric acid and Sodium Hydroxide using Isopropyl Alcohol and Methanol as solvent media to get Stage-2 Intermediate.

Stage-3 : Stage-2 Intermediate is reacted with Paraformaldehyde in presence of Diethylamine and Sodium Ethoxide using Xylene and Ethanol as solvent media for generating intermediate which is finally condensed to obtain Tinosorb-M.


- 95 -


100 Kg of Final Product

Sl.NO.

Raw Materials .

Qty Input

in Kgs.

Qty.Output

in Kgs

Loss In

Kgs/Ltr

Kg of Raw Materials / Kg of Final

Product.

1 4-tert-

Octylphenol

143 Kg 0 0 1.43

2 Acetic acid 56 Kg 0 0 0.56

3 Diethylamine 3.7 Kg 0 0 0.037


Recovered-reuse

30 Ltr

(5%)

6.00

5 Hydrochloric acid (35%)

540 Kg 0 0 5.40

6 o -Nitroaniline 95 kg 0 0 0.95

7 Paraformaldehyde 8.5 kg 0 0 0.085

8 Sodium Methoxide

7 Kg 0 0 0.07

9 Isopropyl alcohol 100 Ltr 95 Ltr

(Recovered-reuse)

5

Ltr(5%)

1.00

10 Sodium Hydroxide

110 kg 0 0 1.10

11 Sodium Nitrite 51 Ltr 0 0 0.51

12 Sulfamic acid 4 kg 0 0 0.04

13 Methanol 1600 Ltr 1520 Ltr (Recovered-

reuse)

80 Ltr 16.00

14 Toluene 750 Ltr 715 Ltr 35 Ltr (5%)

7.50

15 Xylene 510 Ltr 485 Ltr 25 Ltr (5%)

5.10

16 Zinc Powder 85 kg 0 0 0.85

107 Water for process 1700.ltr 1700.ltr( Inorganic

Waste)(for CETP)

0

17.00



waste

(for CETP)

0

5.00


- 96 -

FLOW CHART

o-Nitroaniline Hydrochloric acid (35%) Sodium Nitrite Toluene recovery for reuse Sulfamic acid 4-tert-Octylphenol Evaporation Loss Sodium Hydroxide Water wash for CETP Methanol Acetic acid Toluene Water

Stage-1 in Toluene Zinc Powder Recovered IPA for reuse Sodium Hydroxide Evaporation Loss Isopropyl Alcohol Aquous HCl wash for CETP Hydrochloric acid (35%) Methanol Recovered Methanol for reuse Water

Stage-2 Paraformaldehyde Recovered Xylene for reuse Diethylamine Sol.Recovery Sodium Ethoxide Evaporation Loss Recovered mEthanol Xylene Organic residue Water

Stage-1

Stage-2

Stage-3


- 97 -

3.6: Raw materials

3.6.1 Quantity requirement:

The raw materials required for the manufacture of APIs and Intermediates are appended in the table 3.2 below. Raw materials as listed will be procured as per the production requirement.

Table 3.2: Raw materials requirement

Sl. No.

Product Raw materials

Quantity required Solvents required after

recycling

kg/annum

kg/

batch

kg/

month

kg/

annum

A Herbal Extract

1 Coleus forskholii

extract

Coleus roots powder

1000 10,000 12,000 -

Toluene 3000 30,000 3,60,000 10800

Hexane 300 3000 36000 1800

Dextrin 25 250 3000 -

2 Curcumin Vanillin 111 278 3336 -

Acetyl acetone

37 93 1116 -

Boric oxide 18 45 540 -

TSBB 205 513 6156 -

n-Butylamine

9 23 276 -

Ethylacetate 675 1688 20256 900

Water for

process

1675 4188 50256 -

Water for

reactor washing

500 1250 15000 -

3 Tetrahydro

Curcuminoids

Curcuminoids

166 415 4980 -

Acetone 1660 4150 49800 2400

Palladium Carbon

8 20 240 -

IPA 500 1250 15000 750


N2

Cylinders

1 3 36 -

Water for reactor

washing

500 1250 15000 -


- 98 -

4 Piperine Methyl

Bromocrotonate

100 104 1248 -

Triethyl

Phosphite

95 99 1188 -

Piperidine 65 68 816 -

DMF 300 312 3744 -

Sodium

Methoxide

10 11 132 -

Methanol 500 520 6240 -

Water for Process

700 728 8736 -


500 520 6240 -

5 Tetrahydropiperine

Piperine 71 118 1416 -

Acetone 710 1179 14148 698

Palladium Carbon

3.5 6 72 -

IPA 215 357 4283 199




300 498 5976 -


1 Benzal

koniumchloride

Amine 340 170 2040 -

DM Water 456 228 2736 -

Benzyl chloride

204 102 1224 -

Water for reactor

washing

500 250 3000 -

2 4-nHexyl

Resorcinol


Caproic acid

200 1000 12000 -

Zinc catalyst

10 50 600 -

Raney Nickel

10 50 600 -

Methanol 500 2500 30000 1500

Hexane 500 2500 30000 1500



- 99 -

N2

Cylinders

1 5 60 -

Water for Process

600 3000 36000 -

Water for reactor

washing

500 2500 30000 -

3 4-nButyl

Resorcinol


Butyric acid 194 648 7776 -

Zinc

catalyst

11.1 37 444 -

Raney

Nickel

11.1 37 444 -

Methanol 555 1854 22248 1800

Hexane 555 1854 22248 1500



Water for Process

600 2004 24048 -

Water for

reactor washing

500 1670 20040 -

4 2-methyl resorcinol

1,3-Cyclohexane

dione

158 131 1572 -

Dimethylamine

158 131 1572 -

Formaldehyde

150 125 1500 -

Palladium on Carbon

5%

48 40 480 -

Hydrochlori

c acid

121 100 1200 -

Mesitylene 1425 1183 14196 -

Water for process

600 498 5976 -


500 415 4980 -

5 1,4- cyclohexanedio

ne

Dimethyl Succinate

333 1665 19980 -

Sodium Methoxide

187 935 11220 -


- 100 -

Methanol 720 3600 43200 2160

Con .Sulphuric acid

170 850 10200 -

Ethyl acetate

1670 8350 1,00,200 4800

Charcoal 13 65 780 -

Water for process

1200 6000 72,000 -

Water for

reactor washing

600 3000 36,000 -

6 Tamsulosin HCl

5(2-Amino-Propyl)2-

Methoxy-Benzene-Sulphonami

de

27.5 91.3 1096 -

2-(O-ethoxy-

Phenoxy) ethyl bromide

25 83 996 -

Sodium Carbonate

17 56 672 -

Isopropyl alcohol

125 415 4980 241

Ethyl acetate

175 581 6972 321

Methanol 140 465 5580 281

Charcoal 0.5 1.66 20 -

Con Hcl 7.5 25 300 -

Water for

process

70 233 2796 -

Water for

reactor washing

100 334 4008 -

7 1-ChloroMethyl Naphthalene

Naphthalene

278 1390 16680 -

Para-Formaldehyde

100 500 6000 -

Glacial Acetic acid

290 1450 17400 -

Con .HCl 335 1675 20100 -


- 101 -

Ortho-

Phosphoric acid

160 800 9600 -

Water for

process

2000 10,000 120000 -

Water for

reactor washing

500 2500 30000 -

8 Piroctone Olamine

3,3'-DMAA 125 1250 15000 -

Isononanoyl

chloride

250 2500 30000 -

Anhyd.Alum

inium Chloride

500 5000 60000 -

Sodium methoxide

125 1250 15000 -

Monoethano

lamine

12.5 125 1500 -

Hydroquino

ne

12.5 125 1500 -

Sodium

Carbonate

125 1250 15000 -

Glacial

Acetic acid

125 1250 15000 -

Methanol 750 7500 90,000 4440

Hydroxylamine Hcl

190 1900 22800 -

Con. Sulphuric acid

25 250 3000 -

Ethyl Acetate

1250 12500 150000 7200

EDC 750 7500 90000 4200

Water for

process

1500 15000 180000 -

Water for

reactor washing

750 7500 90000 -

9 2 Ethylhexyl Trizone

2-Ethylhexanol

85 425 5100 -

Acetonitrile 610 3050 36600 1200

Ammonia 25% Solution

6 30 360 -


- 102 -

Cyanuric

chloride

25 125 1500 -

P-nitro benzoic acid

30 150 1800 -

Sodium chloride

6 30 360 -

Methanol 710 3550 42600 2100

Hexane 570 2850 34200 1800

Sodium Carbonate

6 30 360 -

PD/C 10% 5 25 125 -

Perchloroethylene

945 4725 56700 3300

Carbon 5 25 300 -

Sulphric acid

5.5 27.5 330 -

Xylene 400 2000 10000 1200

Water for process

1675 8375 100500 -

Water for

reactor washing

500 2500 30000 -


2-Octyl Phenol

185 309 3708 -

Benzyl chloride

100 167 2004 -

Diethyleneglycol

106 177 2124 -

Diethylamine (40%)

296 494 5932 -

Ethyl

acetate

1400 2338 28056 1403

Phosphorou

s oxy chloride

125 209 2505 -

Sodium hydroxide

155 259 3106 -

Toluene 2670 4459 53507 1102

Water for

process

1600 2672 32064 -

Water for

reactor washing

500 835 10020 -


- 103 -

11 Iscotrizinol 2-

Ethylhexyl 4-Aminobenzo

ate

100 167 2004 -

Acetonitrile 255 426 5110 200

Ammonia 25%

Solution

41 69 822 -

Cyanuric chloride

45 75 902 -

Dimethylformamide

1 1.67 20 -

Hexane 540 902 10822 501

Methanol 420 701 8417 401

P-Nitro benzoic acid

48 80 962 -

Potassium Carbonate

19 32 381 -

Tert-Butylamine

29 49 581 -

Carbon 1 1.67 20 -

Toluene 1210 2021 24248 902

Triethylamine

33 55 661 -

Water for process

1500 2505 30060 -

Water for reactor

washing

500

835 10020 -

12 Tinsorb S 2-

Ethylhexyl Bromide

145 120 1444 -

4-

Bromoanisole

80 65 797 -

Aluminium Chloride

125 104 1245 -

Cyanuric chloride

80 65 797 -

Dimethylformamide

590 490 5876 -

Hexane 110 91 1096 50

Ethylene

Dichloride

725 602 7221 359


- 104 -

Iodine 0.2 0.166 2 -

Isopropyl alcohol

1030 855 10259 548

Magnesium 14 12 140 -

n-Butanol 735 610 7320 349


Methanol 85 71 847 50

P-Nitro benzoic acid

10 8.3 100 -

Sodium carbonate

150 125 1494 -

Tetrahydrofuran

400 332 3984 199

Carbon 3 2.5 30 -

Toluene 1790 1486 17828 897

Vitride (70%) in

Toluene

0.4 0.33 4 -

Water for process

1550 1287 15438 -

Water for reactor

washing

500 415 4980 -

13 Tinsorb-M 4-tert-

Octylphenol

143 119 1424 -

Acetic acid 56 46.5 558 -

Diethylamine

3.7 3 36.9 -

Methanol 600 498 5976 299

Hydrochlori

c acid (35%)

540 448 5379 -

o -

Nitroaniline

95 79 946 -

Paraformald

ehyde

8.5 7 84.6 -

Sodium Methoxide

7 6 70 -

Isopropyl alcohol

100 83 996 50

Sodium Hydroxide

110 91 1096 -

Sodium Nitrite

51 42 508 -

Sulfamic acid

4 3.3 39.6 -


- 105 -

Methanol 1600 1328 15936 797

Toluene 750 622.5 7470 349

Xylene 510 423 5079.6 249

Zinc Powder 85 70.5 846.6 -

Water for

process

1700 1411 16932 -

Water for

reactor washing

500 415 4980 -

3.6.2 SOURCE OF SUPPLY OF RAW MATERIALS:

Subhash Chemical industries pvt ltd.

1. Karnataka Chemical industries pvt ltd,

2. Plant lipid extractions pvt ltd

3. Sainath Chemicals pvt ltd

4. Sri Tirumala chemicals pvt ltd,

5. Bangalore Industrial Oils

6. Nandolia organics pvt ltd

7. Nuchem Dyestuffs (P) limited

8. Shiva pharma chemicals pvt ltd

9. Leo chem. Pvt ltd

10. Avra synthesis pvt ltd

3.6.3 STORAGE FACILITY FOR RAW MATERIALS AND PRODUCTS

Adequate storage facilities are proposed to be provided for the raw materials, products etc.

Table 3.3:- Details of Storage Facilities

Sl. No. Storage Facility for

Facility

1 Raw Materials Warehouse

2 Products Bonded finished good store

3 Industrial Effluent

Sent to Common Effluent treatment for treatment and disposal.

4 Hazardous Waste Process residue is sent to cement industries for co-incineration (as an auxiliary fuel) during the manufacture of cement.

Spent carbon will be disposed for coincineration during the manufacture of cement.


- 106 -

3.6.4 MACHINERY & EQUIPMENT DETAILS

The detailed list of machinery & equipments in the industry are appended in

the tables below 3.4. Table 3.4: List of the Machinery & Equipments DEPARTMENT: PRODUCTION

SL.

NO

EQUIPMENT NAME

EQUIPMENT ID CAPACITY MOC

1. Stainless Steel Reactor

SCAP/SSR/12/001 1KL SS316


SCAP/ SSR/12/002 1KL SS316


SCAP/ SSR/12/003 0.5KL SS316


SCAP/ SSR/12/004 0.25KL SS316


SCAP/SSR/12/005 5 KL SS316


SCAP/SSR/12/006 5 KL SS316

7. Stainless Steel Extractor

SCAP/SSE/12/001 5 KL SS316

8. Stainless Steel Evaporator

SCAP/SSEV/12/001 1.5 KL SS316

9. Stainless Steel

Hydrogenator

SCAP/SSH/12/001 1 KL SS316

10. Glass lined

Hydrogenator

SCAP/GLH/12/001 160 Ltr Glass

lined 11. Glass lined Reactor SCAP/GLR/12/001 1 KL Glass

lined 12. Glass lined Reactor SCAP/GLR/12002 0.5 KL Glass

Lined 13. SS Centrifuge SCAP/CF/12/001 24 inch SS316

14. SS Centrifuge SCAP/CF/12/002 24 inch SS316 15. SS Nutsche filter SCAP/SNF/12/001 26 inch SS316

16. SS Nutsche filter SCAP/SNF/12/002 24 inch SS316 17. PP-Nutshce filter SCAP/PNF-001 32 inch PV

18 Nutshce filter(PVC)-II SCAPPL/PLT/PVCF-002

24 inch PVC

19 Line Filter (Micron) SCAP/LF/12/001 8 inch SS316


- 107 -

20 Vacuum Tray Dryer

(VTD)

SCAP/VTD/001 48 Trays

(150 Kgs)

SS316

21 Multimill (GMP)

SCAP/MM/12/001 100 kg /hr SS316

22 Shifter(sieving) (GMP)

SCAP/SF/12/001 36 inch SS316

23 High Vacuum Pump

(GMP)

SCAP/HVP/002 1500M3/HR SS304

24

Electronic Weighing

(GMP) Balance

SCAP/EWB/12/001 150 KGS SS304

25 GMP Air conditioner(GMP)

SCAP/AC/12/001 5TR NA

26 HVAC (GMP) SCAP/HVAC/12/001 27 HVAC (GMP) SCAP/HVAC12/002

DEPARTMENT: UTILITY

SL. NO

EQUIPMENT NAME

EQUIPMENT ID

CAPACITY

MOC

1. Steam boiler SCAP/SB/12/001 600KG/ hr

MS

2. Steam boiler SCAP/SB/12/002 600KG/ hr

MS

3. DM Water Plant SCAP/DMP/12/001 1000 lts/hr

MS Coated

4. Softener Water Plant

SCAP/SWP/12/001 200LTS /hr

MS

5. Chilling Plant SCAP/CP/12/001 10 Ton NA

6. High Vacuum Pump SCAP/HVP/12/001 750 nm3 SS304

7. Water Vacuum

Pump

SCAP/LVP/12/-01 nm3 SS304

8. DG 63.5KVA SCAP/DG/12/001 63.5 KVA MS

9. Air Compressor SCAP/ACM/12/001 6 Kg/cm2 MS


- 108 -

DEPARTMENT: RESEARCH & DEVELOPMENT

SL. NO

EQUIPMENT NAME

EQUIPMENT ID

CAPACITY

MOC/MAKE

1 TLC UV Chamber SCAP/UVC/12/001 10/10 Frusserl

2 Hydrogenator SCAP/HYD/12/001 10 lts SS316

3 Oil Bath SCAP/OB/12/001 5 LTS MS

4 All Glass Reactor SCAP/GLR/12/001 50 LTS Glass

5 All Glass Reactor SCAP/GLR/12/002 50 LTS Glass

6 Rotary Evaporator SCAP/REV/12/001 3 LTS Heidolp

7 Refrigerator SCAP/DF/12/001 250LTS Kelvinator

8 Electronic Weight Balance

SCAP/EWB/12/001 1.0 KGS Weightron

10 Vacuum Pump SCAP/LVP/12/001 450 M3 MS

11 High Vacuum Pump SCAP/HVP/12/001 750 M3 MS

DEPARTMENT: QUALITY CONTROL

SL. NO

EQUIPMENT NAME

EQUIPMENT ID

CAPACITY

MOC/MAKE

1. IR Moisture Balance SCAP/IRMB/12/001 NA Advance Research

2. TLC UV Chamber SCAP/UVC/12/001 NA Advance Research

3. PH Meter SCAP/PHM/12/001 NA Serwell

4. Microprocessor pH Meter

SCAPPL/QC/MPH-001

NA Microlab

5. KF Titrator SCAP/KFT/12/001 NA Laboratory Service

6. Mille Volt Titrator SCAP/MVT/12/001 NA Laboratory Service

7. Computer SCAP/PC/12/001 NA Zebronics


- 109 -

8. Computer SCAP/PC12/002 NA Zebronics

9. Gas Chromatography

SCAP/GC/12/001 NA Agilent

10. HPLC SCAP/HPLC/12/001 NA Agilent

11. Ultrasonic bath SCAP/USB/12/001 NA Enertech

12. Water Bath SCAP/WB/12/001 NA Equitron

13. Analytical Weighing

Balance

SCAP/AWB/12/001 NA Shimadzo

14. Melting Point

Apparatus

SCAP/MP/12/001 NA Galaxy

15. Hot Air Oven SCAP/HAO/12/001 NA Serwell

3.7 RESOURCE OPTIMIZATION/RECYCLING AND RE-USE ENVISAGED IN THE PROJECT

3.7.1 SOLVENT RECOVERY & RE-USE

Various solvents are proposed to be used during the process of manufacture of APIs & Intermediates. The solvents proposed to be recovered and recycled

during the process of manufacture of each product are detailed in table 3.5.

Table 3.5: Solvent recovery

Sl.No Product Raw materials

Quantity (kg/annum)

Recovered and recycled

Lost

A Herbal Extract

1 Coleus Forskholli extract

Toluene 3,49,200 10800

Hexane 34,200 1800

2 Curcumin Ethyl Acetate 19,350 900

3 TetrahydroCurcumin

oids

Acetone 47400 2400

IPA 14250 750

4 Piperine Methanol 5616 624

5 Tetrahydropiperine Acetone 13446 698

IPA 4084 199


1 Benzal

Koniumchloride

---


- 110 -

2 4-nhexylresercinol Methanol 28500 1500

Hexane 28500 1500

3 4-n Butylresercinol Methanol 21243 1002

Hexane 21042 1203

4 2- Methylresercinol Mesitylene 13496 698

5 1,4 cyclohexanedione

Methanol 41040 2160


6 Tasmsulosin HCL and its itermediates

Isopropyl alchol

4770 241


Methanol 5299 279

7 1-chloromethyl Naphthalene

----

8 Piroctone Olamine Methanol 85560 4440


EDC 85800 4200

9 Ethylhexyl Trizone Acetonitrile 34800 1200

Methanol 40500 2100

Hexane 32400 1800

Perchloroeth

ylene

53400 3300

Xylene 22800 1200



Toulene 52405 1102

11 Iscotrizinol Acetonitrile 4910 201

Hexane 10321 501

Methanol 8016 401

Toulene 23347 902

12 Tinosorb- S Hexane 1046 50

Ethylene Dichloride

6872 359

Isopropyl alcohol

9711 548

Methanol 797 50

Toulene 16932 897

13 Tinosorb -M Methanol 5677 299

Isopropyl alcohol

947 50

Methanol 15139 797

Toulene 7121 349

Xylene 4831 249

Note: * The solvent lost during the process of solvent distillation is mainly due to organic thermal disintegration and in form of residue left behind from the


- 111 -

bottom un-distilled product. Evaporation loss is minimized by the passage of chilled water through the condenser.

SOLVENT RECOVERY SYSTEM

After the reaction is complete the solvents are recovered in a distillation unit.

The distillation unit has two condensers in series (shell and tube type).

The first condenser is passed with chilled cooling tower water at 7-12 oC, while the second condenser will be passed with chilled brine solution at -10 - 200 C as coolants.

After the vapors are condensed, the condensate along with un-condensed vapors is passed through a trap which is cooled externally with chilled

water. The vents of condenser and receiver are connected to scrubber system. All the reaction vessels and centrifuges are connected to a common line.

These fumes and exhausts are sucked by ID fan and scrubbed by alkali solution.

The air after scrubbing is let out into the atmosphere and the scrubbed water is sent to CETP for further treatment.

This wet scrubber absorbs acidic vapors, traces of solvents etc. and

purified gas stream is let out into the atmosphere

Fig 3.: Typical solvent recovery system

Condenser 2

Condenser 1

Chilled water

Cooling tower water

Distillation

column

Receiver

To scrubber

Recovered solvent

Residue to storage


- 112 -

3.7.2 SPENT CARBON

Spent carbon is used during the process of manufacture of different APIs & intermediates. The spent carbon will be disposed to co-incinerator as axilaury

fuel during manufacture of cement. The detailed list of the quantities is appended in table 3.6 below

Table 3.6: Spent carbon recovery and disposal

Sl. No.

APIs Quantity of spent carbon, kg/annum

1 Tetrahydro Curcuminoids

a. Palladium carbon

240

2 Tetrahydro piperine

a.Palladium Carbon

70


478

5 1,4 Cyclohexanedion a. Charcoal

780

6 Tamsulin HCL a. charcoal

20

7 Ethylhexyl trizone a. carbon

300

8 Iscotrizinol a. carbon

21

9 Tinsorb S a.carbon

30

TOTAL 1939

3.7.3 DOMESTIC SOLID WASTE RE-USE

The total quantity of domestic wastes generated is about 10 kg/day which will be segregated at source, collected in bins and composted. The composted waste will be used as manure for landscape development.

3.8 WATER, ENERGY/POWER REQUIREMENT & SOURCE

3.8.1 Water The water demand is met from Bore well water supply. The requirement of

water for the unit is for domestic, industrial purposes. Details are appended in section 3.9.1 later in the report.


- 113 -

3.8.2 Power The total power requirement of the industry is 65 kVA. Further diesel generator

of 63.5 kVA capacity is proposed to be installed to serve as an alternative source of power supply to this unit.

3.9 WASTES GENERATED & SCHEME FOR THEIR MANAGEMENT/DISPOSAL 3.9.1 Water demand and wastewater/effluent discharge

Source of water supply: Borewell Total number of employees: 40 people Per capita water demand: 45 LPCD

The total quantity of water required for the industry is about 12 KLD. The break-up of the consumption of water is as presented below in Table 3.7

Table 3.7: Water consumption and discharge

Sl. No.

Purpose Total Quantity LPD

Recirculation /Recycle LPD

Loss/Consumption/Evaporation /Daily Make Up Water Etc LPD

Wastewater Generation In LPD

I Domestic (Toilet, Canteen etc.)

1800 - 1800 1620

II. Gardening/Landscape development

1,000 - 1000 -

III Industrial purpose 23,800 14500 9200 7250

1 Process 3000 - 3000 3000

2 Washing/ Cleaning

2,000 - 2000 2,000

4 DM water with R & D 500 - 500 500

3 Softener/rejects 8000 (7000-

6300=700 )

6300 700 Make up water +1000 for softner

1150 (Softener

rejects and boiler blow-

down)

Boiler feed for 600 Kg/hr 2 nos boiler

5 Cooling tower – 1 no. 10,000 (10,000-

8400=1600)

8400 1600 Make up water

200 (bleed off)

6 Scrubber – 1 no. 400 - 400 400

Grand Total 26,600 14,700 12,000 8870

Note: LPD – liter per day; KLD – kilo liter per day


- 114 -

The treatment methods and the final disposal of each type of wastewater generated is appended in the table 3.8 below

Table 3.8: Sewage/effluent treatment and discharge

Sewage/effluent generated from

Treatment units provided Final disposal point

(a) Domestic Domestic sewage generated will be treated in septic tank and soak pit.

Recycle and on land irigation

(b) Industrial The effluent is collected in the collection tank and sent

to Common Effluent treatment Plant (CETP).

Industrial effluent is treated in common effluent

treatment plant (CETP) for treatment and disposal.


- 115 -

LANDSCAPING 1,000 LPD

BOREWELL WATER SUPPLY

Cooling tower make up 1600 LPD

(10-1.6=8.4)KL recirculation in

the system

Treated in septic tank and soak pit

WATER CONSUMPTION 12,000 LPD

DOMESTIC WATER DEMAND 1,800 LPD

Scrubber

400 LPD

7250 LPD WASTEWATER GENERATED IS HANGED OVER TO M/S. COMMON EFFLUENT TREATMENT PLANT MALUR PRIVATED LIMITED, KIADB INDUSTRIAL AREA, MALUR FOR

TREATMENT AND DISPOSAL

Process effluent and DM rejects

3500 LPD

Washing effluent

2000 LPD

Softner 8000 LPD

Washing/ Cleaning 2000 LPD

Scrubber effluent 400 LPD

INDUSTRIAL WATER DEMAND 23900 LPD- Start up requirement Daily requirement after recycling:

23900-(6300 +8400) = 9200 LPD

Fig 3.4: Water balance chart

DM water with

R&D 3500 LPD

Process 3000 LPD

Domestic wastewater 1620 LPD

Boiler make up water 400 LPD (7-6.3=0.7) KL

200 LPD bleed off

Softner Reject

1000 LPD

Process condensate 6300 LPD

1400 LPD Loss through evaporation

150 LPD blow down down

550 LPD

Loss


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3.9.1.1 PRODUCT-WISE WATER CONSUMPTION, DISCHARGE, BYPRODUCTS & INORGANIC SALTS GENERATION

Table 3.9: Product-wise water consumption and effluent discharge

SL.N

o

Product

Batch-wise water consumption, discharge, Byproduct & Inorganic salt

generation

No. of batches

/month

Total water consumption

(L/month)

Total effluent discharge

(L/month)

Utility of water

Water consumpt

ion (L/batch)

Effluent discharge

(L/batch)

A Herbal Extract

1 Coleus Forskholli

Extract

Process - - 10

- -

Cleaning 300 200 3000 2000

Total 300 200 3000 2000

2 Curcumin Process 1,675 1,675 2.5

4188 4188

Cleaning 500 500 1250 1250

Total 2175 2175 5438 5438

3 Tetrahydro

curcuminoids

Process - -

2.5

- -

Cleaning 500 500 1250 1250

Total 500 500 1250 1250

4 Piperine Process 700 700

1.04

728 728

Cleaning 500 500 520 520

Total 1200 1200 1248 1248

5 Tetrahydro Piperine

Process - -

1.66

- -

Cleaning 300 300 498 498

Total 300 300 498 498


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1 Benzal Koniumchloride

Process - - -

0.33

- -

Cleaning 500 500 165 165

Total 500 500 165 165

2 4- hexyl Resorcinol

Process 600 600 5

3000 3000

Cleaning 500 500 2500 2500

Total 1100 1100 5500 5500

3 4 – n Butyl Resorcinol

Process 600 600 3.34

2004 2004

Cleaning 500 500 1670 1670

Total 1100 1100 3674 3674

4 2 Methyl

Resorcinol

Process 600 600

0.83

498 498

Cleaning 500 500 415 415

Total 1100 1100 913 913

5 1,4 cyclohexanedione

Process 1200 1188 5

6000 5940

Cleaning 600 600 3000 3000

Total 1800 1788 9000 8940

6 Tamsulion HCL

Process 70 70 3.32

233 233

Cleaning 100 100 332 332

Total 170 170 565 565

7 1-ChloroMethyl

Napthalene

Process 2000 2000 4.16

10,000 10,000

Cleaning 500 500 2500 2500

Total 2500 2500 12500 12500

8 Piroctone olamine

Process 1500 1500

10

15000 15000

Cleaning 750 750 7500 7500

Total 2250 2250 22500 22500


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9 Ethylhexyl

Trizone

Process 1675 1675

5

8375 8375

Cleaning 500 500 2500 2500

Total 2175 2175 10875 10875

10 Benzethoniu

m chloride

Process 1600 1600

1.67

2672 2672

Cleaning 500 500 835 835

Total 2100 2100 3507 3507

11 Iscotrizinol Process 1500 1500 1.67

2505 2505

Cleaning 500 500 835 835

Total 2000 2000 3340 3340

12 Tinsorb – S Process 1550 1550 0.83

1287 1287

Cleaning 500 500 415 415

Total 2050 2050 1702 1702

13 Tinsorb -M Process 1700 1700 0.83

1411 1411

Cleaning 500 500 415 415

Total 2200 2200 1826 1826

GRAND TOTAL 87,501 86,441

Note: Considering no. of working days/month = 25

1. Daily water consumption from process and washings/cleaning = 87,501/25 = 3,500 LPD 2. Daily effluent discharge from the process and washings = 86,441/25 = 3,457.64 LPD 3. Process water demand = 57,901/25 = 2,316.04 LPD or say 2,317 LPD

4. Process effluent discharge = 57,841/25 = 2313.64 LPD or say 2,314 LPD 5. Cleaning/washing water demand = 29,600/25 = 1,184 LPD

6. Cleaning/washing effluent discharge = 28,600/25 = 1,144 LPD


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3.9.1.2 RAINWATER HARVESTING & GROUNDWATER RECHARGING

The total amount/quantity of water i.e., received in the form of rainfall over an

area is called the rain water endowment of that area, out of which the amount

of water that can be effectively harvested is called the rain water harvesting

potential.

Rain water harvesting potential = Intensity of rainfall (m) x Roof area x

Impermeability factor

The collection efficiency accounts for the fact that all the rain water falling over an area can not be effectively harvested due to losses on account of

evaporation, spillage or run off etc., According to the data available from the Indian Meteorological Department, the

Average annual rainfall around month of September = 194.80 mm. Assuming that about 90 % Rainfall can be effectively harvested.

Number of Rainy Days = 9.3

Therefore the I.R = 194.80/9.3= 20.94 mm/day or 0.02094 m/Day or 0.021

m/day

Quantity of roof top rain water harvested from the project:

The Ground Coverage area of the proposed project is about 465 sq m.

For rain water harvesting consider 75% of this total area = 349 sq m.

Quantity of Rain Water that can be harvested from the proposed project is calculated as below.

Water Harvested per Year = Mean Annual Rainfall x Area x Collection Efficiency = 0.021 x 349

= 7.329 or say 8 m3/day

However, it proposed to initially utilize the entire quantity of the rainfall

potential by providing adequate storage facilities (RCC tank of 100 m3

capacity).

The amount of storm water that the landscaped/open area will produce can be

determined by considering the impermeability factor to be 0.3.

Q = 0.021 x 279 x 0.3

= 1.8 m3/day


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The amount of storm water that the paved area will produce can be determined

by considering the impermeability factor to be 0.3.

Q = 0.021 x 186 x 0.9

= 3.51 m3/day or say 3.6 m3/day

The total amount of storm water = landscaped area + paved area

= 1.8 + 3.6 m3/day

= 5.4 m3/day

The project Proponents will also provide recharging pits along the inner

periphery of the boundary wall. Each recharging pit will be of size 1.2 m dia x

2.5 m deep spaced at 20 m center to center. These recharging pits are filled

with graded media comprising of boulder at bottom and with coarse aggregates

to facilitate percolation of harvested rainwater to recharge ground water table.

The recharge pits are interconnected in such a way that the rain led to the first

recharge pit is also led to the next pit.

3.9.1.3 PROCESS EFFLUENT CHARACTERISTICS The characteristics of the effluent generated during the manufacturing process

is indicated in the tables below 3.1

Table 3.10: wastewater characteristics

Parameter Results

pH 6.2-6.5

Biological Oxygen Demand,

mg/L

1600 – 3,000

Total dissolved solids, mg/L 10,500 –19,500

Total suspended solids, mg/L 130-180

Chemical Oxygen Demand,

mg/L

1,000 – 1,800

Chlorides as, Cl mg/L 500

Suphates as, SO4 mg/L < 1500

Oil & grease < 1.0

3.9.1.4 STORAGE FACILITIES PROVIDED FOR INDUSTRIAL EFFLUENTS

The industrial effluent is proposed to be collected in a collection tank and sent to Common Effluent Treatment Plant for treatment and disposal.

The industry proposes to provide adequate storage facilities for the industrial effluents. The details of which are appended below.


- 121 -

Storage facilities at the

project site

The industrial effluent is transferred to

collection tanks through ceramic pipes with secondary containment.

3.9.2 Air pollution sources

The major air pollution sources from the industry are DG set and boiler apart from the process sections. These sources are provided with stacks of adequate

height so as to disperse the emanating flue gases containing SPM, oxides of sulfur and nitrogen without affecting the ground level concentrations and

packed column scrubbers (1 no.s) are proposed to the process section & R&D facility with adequate stack height as per the regulatory requirements.

The sources of air pollution, type of fuel used, fuel consumption and chimney

heights for each of the air pollution sources of the proposed project are indicated in the table 3.11 below.

Table 3.11: Air pollution sources, fuel consumption and chimney height details

SI. no.

Stack attached to

Fuel used Fuel consumption

Number of

stacks

Stack/s height

Air pollution control unit

Predicted emissions

1 Process section

- - 1 5 m ARL

Packed column

scrubber – 1 no.

Acid mist/

VOCs

2 Steam boiler – 600

kg/hr capacity

– 2 no.s

Diesel 45 L/hr 1 30.5 m AGL

Stack SO2, NOx, SPM

4 D.G. set – 63.5

kVA – 1 no.

HSD 12.7 L/hr 1 7 m AGL

Stack SOx, NOx, SPM


- 122 -

* Stack height calculation for DGs Formula adopted for stack height calculation

H = 14(Q)0.3

Where, H is stack height Above Ground Level Q is sulfur content in exhaust in kg/hr (As per Handbook on Environmental Legislations and Technologies)

Fuel consumption = 12.7 L/hr = 0.0127 m3/hr Sulfur content in HSD = 0.25%

Density of sulfur = 2046 kg/m3 Therefore, Q = 0.0127 x (0.25/100) x 2046 = 0.0649 kg/hr

Therefore, height of chimney = 14 (0.0649)0.3 = 6.16 m AGL Or say 7 m AGL Therefore it is proposed to provide 1 stack of height 7 m AGL for one diesel generator of 63.5 kVA capacity. ** STACK HEIGHT CALCULATION FOR BOILERS

Existing

Formula adopted for stack height calculation

H = 14(Q)0.3

Where, H is stack height Above Ground Level Q is sulfur emissions in kg/hr

0.6 TPH BOILER

Type of fuel used – diesel Sulfur content in diesel is 1.8% Specific gravity of sulfur = 2.046

Density of sulfur = 2046 kg/m3 Fuel consumption = 45 L/Hour = 0.045 m3/Hr Therefore, Q = 0.045 x (1.8/100) x 2046 = 1.65 kg/Hr

Therefore, Height of chimney = 14 (1.65)0.3 = 16.26 m AGL

Or say 17 m AGL However a stack of height 17 m AGL is installed (combined stack for 0.65 TPH

boiler & thermic fluid heater).


- 123 -

The exhaust temperature will be nearly ambient and adequate port holes with access platform will be provided as per KSPCB guidelines as under

1. Location of port holes and approach platform

The sampling porthole will be provided at a distance equal to at least eight times the stack diameters downstream and two diameters upstream from source of low disturbance such as bend, expansion, and construction valve

fitting or visible flame for rectangular stacks. The equivalent diameter is calculated from the following equation Equivalent diameter = 2 (Length x Width)

(Length x Width)

2. The diameter of the sampling port will be minimum 3”. Arrangement will be made to close the port hole firmly during the period when it is not used for sampling.

3. An easily accessible platform will be provided to accommodate 3 to 4 persons

to conveniently sample stack emissions from the portholes. Ambient air quality and stack emission monitoring

Ambient air quality monitoring will be conducted once in a month as per the guidelines of KSPCB for SPM, RSPM, SOx, NOx, HC and CO and the record of monitoring reports will be maintained and made available to authorities.

Similarly stack monitoring will also be conducted for SOx.

Scrubber details Scrubber systems are a diverse group of air pollution control devices that can

be used to remove particulates and/or gases from industrial exhaust streams. Traditionally, the term "scrubber" has reference to pollution control devices that used liquid to "scrub" unwanted pollutants from a gas stream. Recently,

the term is also used to describe systems that inject a dry reagent or slurry into a dirty exhaust stream to "scrub out" acid gases. Scrubbers are one of the

primary devices that control gaseous emissions, especially acid gases.

Wet scrubber is a form of pollution control technology in which the polluted gas stream is brought into contact with the scrubbing liquid by spraying it with the

liquid, by forcing it through a pool of liquid, or by some other contact method, so as to remove the pollutants.

The design of wet scrubbers or any air pollution control device depends on the industrial process conditions and the nature of the air pollutants involved. Inlet gas characteristics and dust properties (if particles are present) are of

primary importance. Scrubbers can be designed to collect particulate matter and/or gaseous pollutants. Wet scrubbers remove dust particles by capturing them in liquid droplets; remove pollutant gases by dissolving or absorbing

them into the liquid.


- 124 -

Any droplets that are in the scrubber inlet gas must be separated from the

outlet gas stream by means of another device referred to as a mist eliminator or entrainment separator (these terms are interchangeable). Also, the resultant

scrubbing liquid must be treated prior to any ultimate discharge or before being reused in the plant.

There are numerous configurations of scrubbers and scrubbing systems, all designed to provide good contact between the liquid and polluted gas stream. The process and solvent recovery sections are provided with scrubber to scrub

the fumes and vapors generated in order to remove such emissions before it is let out into the atmosphere.

Packed column scrubber specifications

Air volume – 6000 CMH Velocity through duct – 8 m/s

Scrubbing pad height – 1 m Velocity through scrubbing pads – 1.5 m/s Nozzle type – Full cone type

Nozzle spray area – 0.07 m2 Spray chamber height – 350

Fig 3.5: Column scrubber


- 125 -

3.9.3 Noise generation and its management

The major source of noise pollution in the industry is the DG set for which acoustic enclosure is proposed. Also ambient noise levels will be ensured

within the ambient standards by inbuilt design of mechanical equipment and building apart from vegetation (tree plantations) along the periphery and at various locations within the industry premises.

3.9.4 Solid waste generation and management

The quantity of solid waste generated from the industry is calculated as below in the table 3.12

Table 3.12 Solid waste generation

Total no. of employees 40

Assuming per capita solid waste generation rate as 0.25 kg/capita/day

Quantity of solid waste generated 10 kg/day

Organic solid waste : 60 % of the

total waste

6 kg/day

Inorganic solid waste : 40 % of the total waste

4 kg/day

Disposal of domestic solid waste The domestic wastes are segregated at source,

collected in bins and composted.

3.9.5 Hazardous raw materials used in the manufacturing process and hazardous waste generation and management 3.9.5.1 HAZARDOUS RAW MATERIALS

The following raw materials used during the process of manufacture of APIs and Intermediates are hazardous in nature according to Manufacture, Storage and Import of Hazardous Chemical (Amendment) Rules, 19th January 2000, Schedule I, Part II

Table 3.13: Hazardous raw materials

Hazardous raw material Sl. No. as per Manufacture, Storage and Import of Hazardous Chemical (Amendment) Rules, 19th January 2000, Schedule I, Part II

Toulene 628

Hexane 306

Acetone 4

Piperdine 514


- 126 -

Benzyl chloride 67

Dimethylamine 215

Formaldehyde 295

Hydrochloric acid 313

Mesitylene 362

Sulphuric Acid 591

Ethyl Acetate 247

Isopropyl alcohol 334

Napthalene 417

Acetonitrile 7

Iodine 323

3.9.5.2 HAZARDOUS WASTE GENERATION AND MANAGEMENT

The hazardous wastes generated during the process of manufacture of different APIs are stored at hazardous waste storage area and sent to cement industries

for co-incineration (as an auxiliary fuel) during the manufacture of cement. The quantities of hazardous waste generated from various processes are shown in the following table 3.14.

Table 3.14 : Miscellaneous types of hazardous waste generated:

Sl. No.

Particulars Quantity of hazardous waste

generated kg/annum

Disposal Options Category

1 Waste oil generation from DG set

240 L Disposed through authorized recyclers

5.1

2 Residue from solvent recovery plant

4500 Disposed through Cement industries for co incinerations

28.1

3 HDPE Containers 6,00 nos Disposed through authorized recyclers

33.3

4 Inorganic salt 3,000 Dispoded to TSDF for scientific landfill.

34.3

5 Spent carbon 1,939 Disposed through Cement industries

for co incinerations

28.2


- 127 -

3.9.5.3 Others

Spent carbon

Table: 3.15 Quantity of spent carbon generation from manufacturing process

Sl. No.

APIs Quantity of spent carbon,

kg/annum

1 Tetrahydro Curcuminoids a. Palladium carbon

240

2 Tetrahydro piperine a. Palladium Carbon

70


478

5 1,4 Cyclohexanedion b. Charcoal

780

6 Tamsulin HCL b. charcoal

20

7 Ethylhexyl trizone b. carbon

300

8 Iscotrizinol

b. carbon

21

9 Tinsorb S

a.carbon

30

TOTAL 1939

Spent carbon is used during the process of manufacture of different APIs &

intermediates. The spent carbon will be disposed for co-incineration in cement manufacturing.


- 128 -

Table 3.16: Characteristics of hazardous waste

Sl. No

Parameter Unit Method Observation / Result

CPCB Std. and WLT/TCLP Limit for Direct Landfill

1 Physical state - Visual observation Solid -

2 Color - Visual observation Light grey -

3 Texture - Visual observation Powder & lump

-

4 Bulk density gm/cc ASTM Std: D 5057 -1990 (Reapproved

2001)

1.25 -

5 Paint Filter

Liquid Test

- SW-846:9095 A Pass Pass

6 pH (at 29.60 C) - SW-846:9040B, 9045

C

9.51 4.0 - 12.0

7 Calorific Value kcal/kg IS:1350 (Part II)-1970

(Reaffirmed 1983)

2400 <2500.0

8 Flash Point 0C SW-846:1020A 62 >60.0

9 Loss on drying at 103-1050 C

% (w/w) Std.Methods:2540 B 10% -

10 Loss on ignition at 5500 C (dry

basis)

% (w/w) Std. Methods:2540 E <10.0 Non-Bio degradable

<3.0 Bio degradable

< 20.0 (non-biodegradable

) <5.0

(biodegradable)

11 Reactive

cyanide

mg/kg SW-846: Ch.7 (7.3.3),

9014

<MDL -

12 Reactive

sulfide

mg/kg SW-846: Ch.7 (7.3.4),

9034

<10 -

13 Water soluble

compounds except salts – in WLT extract

% (w/w) DIN:38414 Part 4 (S4)

Std. Methods:2540 B,E

2.0

0.5

<10.0

14 Oil and grease (As n-hexane

extractable)

% (w/w) SW-846:3540C, 9071A Nil <4.0

15 Cyanide-total mg/kg SW-846:9010B, 9014 1<MDL -

15 a Cyanide-WLT mg/L DIN:38414 Part 4 (S4)

Std. Methods:4500-CN-

<MDL <2.0


- 129 -

C SW-846:9014

16 Fluoride-Total mg/kg Std.Methods:4500-F-

B,D <0.1 -

16 a Fluoride-WLT mg/L DIN:38414 Part 4 (S4) Std.Methods:4500F-

B,D

<1.0 <50.0

17 Nitrate-WLT mg/L DIN:38414 Part4 (S4) Std.Methods:4500-

NO3- E

<5 <30.0

18 Ammonia -

WLT

mg/L DIN:38414 Part4 (S4)

Std.Methods:4500-NH3 B,C

<10 <1000.0

19 Arsenic-Total mg/kg SW-846:3050B Std.Methods:3500-As B

<10 -

19 a Arsenic- WLT mg/L DIN:38414 Part 4(S4) SW-846:3010A

Std.Methods:3500-As B

<0.02 <1.0

20 Cadmium –Total

mg/kg SW-846:3050B,7130 <0.5 -

20 a Cadmium - WLT

mg/L DIN:38414 Part4(S4) SW-846:3010A,7130

<0.01 <0.20

21 Chromium –

Total

mg/kg SW-846 :3050 B, 7190 3<MDL -

21 a Chromium

(VI)-WLT

mg/L DIN:38414 Part4(S4)

Std.Methods:3500-Cr B

<MDL <0.50

21 b Chromium-TCLP

mg/L SW-846:1311 SW-846:3010A, 7190

<0.05 <5.0

22 Copper-Total mg/kg SW-846:3050B, 7210 <MDL -

22 a Copper-WLT mg/L DIN:38414 Part4(S4)

SW-846:3010A, 7210

<0.05 <10.0

23 Lead-Total mg/kg SW-846:3050B, 7420 <MDL -

23 a Lead-WLT mg/L DIN:38414 Part4(S4) SW-846:3010A, 7420

<0.05 <2.0

25 Nickel-Total mg/kg SW-846:3050B, 7520 <MDL -

25 a Nickel-WLT mg/L DIN:38414 Part4(S4)

SW-846:3010A, 7520

<MDL <3.0

27 Zinc-Total mg/kg SW-846:3050B, 7950 <0.5 -

27 a Zinc-WLT mg/L DIN:38414 Part4(S4) SW-846:3010A, 7950

<MDL <10.0

28 Phenol-Total mg/kg SW-846:9065 <MDL -

28 a Phenol-WLT mg/L DIN:38414 Part4(S4)

SW-846:9065

<0.1 <100.0


- 130 -

3.9.5.4 STORAGE FACILITIES FOR HAZARDOUS WASTE

The industry proposes to provide adequate storage facilities for the hazardous

wastes. The details are appended below.

Storage facilities at the project site

A designated impervious structure (sealed drums under cover roof) is proposed at the

project site for collection and storage of hazardous waste.

Hazardous waste disposal Process residue is sent to cement industries for co-incineration (as an auxiliary fuel) during

the manufacture of cement.

The spent carbon will be disposed for co-incineration in cement manufacturing.


- 131 -

3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING

A schematic representation of the overall feasibility and environmental

assessment process is shown in Figure 3.6.

Fig 3.6: Feasibility & environmental assessment process

Significant

Not

Economic

Feasibility study conducted for newly proposed industry

Statement of intent by proponent

Guidelines for EIA by SEAC/MoEF

Abandon project

Determine the coverage of the EIA - scoping

Describe the environment – baseline study

Describe the project

Identify the impacts

Evaluate the impacts

Mitigation

Preventive measures

Prepare draft EIS

FINAL EIS REPORT

CONSIDER ALL PHASES OF PROJECT –

CONSTRUCTION, DEVELOPMENT, INSTALLATION &

FINAL OPERATION/ PRODUCTION

SO

CIO

-ECO

NO

MIC

ISSU

ES

MO

NIT

OR R

EVIE

W


- 132 -

CHAPTER 4

SITE ANALYSIS 4.1 CONNECTIVITY

Fig 4.1: Google map showing connectivity

PROJECT SITE

Heelalige Railway Station


- 133 -

Table 4.1: Connectivity from the project site:

Sl. No.

Road Distance from the

project site (km)

Direction w.r.t.

project site

1 NH 7 (Bangalore hydrabad highway)

2 West

2 Banerghatta national park 16 South west

3 Raysandra lake 3 North west

4 Chikka tagur lake 3 East

5 Veersandra lake 2 South west

6 Hebbagodi lake 2.5 South

7 Kamasandra Lake 2.5 South East

8 Heelalige railway station 4.5 South east

9 Kempegowda International

Airport

39 South

Note: All distances mentioned are aerial.

4.2 LAND FORM, LAND USE & OWNERSHIP M/s. Somu Chemicals and Pharmaceuticals Pvt Ltd., #20, 29th main, 1st

phase, 2ndstage B.T.M layout Bangalore-76. Is herbal extract an Active Pharmaceutical Ingredients (APIs), intermediates manufacturing industry with

R&D activity is proposed to be established at Shed No: B4 & B5, KSSIDC Industrial Estate, Veerasandra II Stage, Hosur Road, Anekal Taluk, Bangalore -560 100

“M/s. Somu Chemicals and Pharmaceuticals Pvt. Ltd.,” has entered into a lease agreement with KSSIDC & a copy of the lease deed is attached as

Annexure C.


- 134 -

4.3 TOPOGRAPHY

M/s. Somu Chemical & Pharmaceuticals Pvt. Ltd., is located at latitude of 12°50'51.89"N & longitude 77°41'21.33"E at an elevation of 922 m above MSL.

The topo map showing the location of the project site is appended as fig 4.2.

Fig 4.2: Topo map

Source: Survey of India; Scale: 1:50000

4.4 EXISTING LAND USE PATTERN

Table 4.2: Existing land-use pattern

Sl. No.

Particulars Details Distance from the project

site (km)

Direction w.r.t.

project site

1 Agriculture Minor activities - scattered

Beyond industrial

area

-

2 National park,

forest

Banerghatta national

park

16 South West

3 Water bodies Raysandra lake 3 North west

Chikka tagur lake 3 East

Veersandra lake 2 South west

Hebbagodi lake 2.5 South

Kamasandra Lake 2.5 South East

Heelalige railway station 4.5 South east


- 135 -

Note: a) All distances mentioned are aerial.

b) The project is a notified by KSSIDC, Karnataka Govt. industrial area. A copy of the Allotment/Possession Certificate is enclosed as Annexure -B


- 136 -

Fig 4.3: Google map showing surrounding environmental features

RAYASANDRA LAKE

VEERSANDRA LAKE

PROJECT SITE

CHIKKA TAGUR LAKE

HEBGODI LAKE

KAMSANDRA LAKE


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4.5 EXISTING INFRASTRUCTURE

The list of existing infrastructure at the project site is 1. Water supply from Bore well

2. Power supply will be from BESCOM 3. Storm water drainage system is proposed 4. Domestic sewage & domestic garbage treatment is proposed in-house

5. Industrial wastewater & hazardous waste generated from the industry is proposed to be out-sourced to CETP

4.6 METEOROLOGICAL DATA

Assessment of the micro and macro meteorology is important from the standpoint of understanding the nature and extent of air pollution in the study area. Climate has an important role in the build-up of pollution levels in

Bangalore. The climatic condition of the area may be classified as moderately or seasonally dry, tropical or temperate savanna climate with four seasons in a

year. Winter is critical for air pollution build-up because of frequent calm conditions with temperature inversions resulting in poor atmospheric mixing, natural ventilation and high emission loads during evening traffic peaks.

The classification of months according to the seasons is given in the following table

Season Period

Summer March to May

Monsoon June to September

Post monsoon October to November

Winter December to February

The metrological data reflecting minimum, maximum temperature in 0C,

relative humidity in %, rainfall in mm/hr, wind speed in m/s, mixing height in m, cloud cover in tenths and atmospheric pressure in mb for the year 2011 obtained from modeling studies carried out using U.S. EPA AERMOD

dispersion model, 1996 – 2011 Lakes Environmental Software, Version 7.1.0 has been appended as table 4.3.


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Table 4.3: Meteorological data of Bangalore for the year 2015

Month Temperature 0C

Relative humidity %

Precipitation rate (mm)

Atmospheric Pr. (mb)

Wind speed

(m/s)

Inversion / mixing

height (m)

Cloud cover

(tenths)

Min Max Max Min Min Max Min Max Min Max Day Night Min Max

Jan 17 25 84.8 58.3 0 0 909 919 0 6.7 2303 2477 2 10

Feb 13 20 76.9 44.8 0 12 908 915 0 5.1 2517 1786 2 5

Mar 15 25 69 38.8 0 90 907 917 0 6.2 2798 2057 2 6

Apr 12 27 76.7 50.7 0 0 908 914 0 5.1 2910 1799 2 5

May 19 27 82.7 61.0 0 48 905 913 0 6.2 3319 2317 2 5

June 15 21 88.6 71.7 0 21 904 913 0 10.3 2828 4000 2 10

July 18 21 89 75.5 0 18 904 912 0 8.7 2691 3638 2 10

Aug 17 28 88.9 74.5 0 81 904 912 0 7.2 2678 2779 3 10

Sept 17 18 91.4 75.3 0 192 905 912 0 7.2 2802 2801 2 10

Oct 22 24 88.5 73.5 0 75 904 913 0 5.7 2575 2046 3 10

Nov 20 21 93.5 78.1 0 93 905 915 0 6.2 2177 2247 2 10

Dec 17 22 87.6 66.8 0 0 906 914 0 6.7 1756 2522 2 10


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4.6.1 Temperature

The mean maximum temperature is observed at (32°C) in the month of May and the mean minimum temperature at (11.8°C) is observed in the month of

December. In the summer season the mean minimum temperature is observed during the month of March (16.4°C). During the monsoon the mean maximum temperature is observed to be 30.9°C in the month of June with the mean

minimum temperature at 17°C during August. By the end of September with the onset of post monsoon season (October - November), day temperatures drop slightly with the mean maximum temperature at 28.8°C in October and

mean minimum temperature is observed at 16.8°C for both October & November. The values are presented in table 4.3.

4.6.2 Relative humidity

Minimum and maximum values of relative humidity have been recorded. The minimum humidity is observed to be at 38.8% in the month of March and the

maximum is 91.4% in the month of September. The mean minimum values of humidity during summer, monsoon, post-monsoon and rainy seasons are 38.8%, 71.7%, 73.5% & 44.8% during the months of March, June, October and

February respectively. Similarly the maximum values are 82.7%, 91.4%, 93.5%, 87.6% in the months of May, September, November & December during the summer, monsoon, post monsoon & winter seasons. The values are presented in

table 4.3.

4.7.3 Rainfall The monsoon in this region usually occurs twice in a year i.e. from June to

September and from October to November. The maximum annual rate of precipitation over this region ranges between 1.02 to 4.83 mm/hr.

4.6.4 Atmospheric pressure

The maximum and the minimum atmospheric pressures are recorded during all seasons. In the summer season, the mean maximum and minimum pressure values are observed to be 917 mb in the month of March and 905 mb

in the month of May respectively. During monsoon season, the maximum pressure is 913 mb and minimum 904 mb. The maximum pressure during the

post-monsoon season is observed to be 915 mb in November and minimum pressure is 904 mb in the month of October. During the winter season the minimum atmospheric pressure is 906 mb in December and the maximum is

919 mb in the month of January. The values are presented in table 4.3.


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4.6.5 Wind The data on wind patterns are pictorially represented by means of wind rose

diagrams for the entire year as figure 4.4 (for different seasons).

Fig 4.4: Wind rose diagrams 1. March to May (summer season)

WRPLOT View - Lakes Environmental Software

WIND ROSE PLOT:

Wind rose diagram - summer season

COMMENTS:

MODELER:

M/s. Aquatech Enviro Engineers

DATE:

1/18/2012

PROJECT NO.:

NORTH

SOUTH

WEST EAST

4%

8%

12%

16%

20%

WIND SPEED

(m/s)

>= 11.1

8.8 - 11.1

5.7 - 8.8

3.6 - 5.7

2.1 - 3.6

0.5 - 2.1

Calms: 9.19%

TOTAL COUNT:

2208 hrs.

CALM WINDS:

9.19%

DATA PERIOD:

Start Date: 3/1/2010 - 00:00End Date: 5/31/2010 - 23:00

AVG. WIND SPEED:

2.73 m/s

DISPLAY:

Wind SpeedFlow Vector (blowing to)

1/18/2015


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2. June to September (monsoon season)


WIND ROSE PLOT:

Wind rose diagram - monsoon season

COMMENTS:

MODELER:


DATE:

1/18/2012

PROJECT NO.:

NORTH

SOUTH

WEST EAST

7%

14%

21%

28%

35%

WIND SPEED

(m/s)

>= 11.1

8.8 - 11.1

5.7 - 8.8

3.6 - 5.7

2.1 - 3.6

0.5 - 2.1

Calms: 1.91%

TOTAL COUNT:

2928 hrs.

CALM WINDS:

1.91%

DATA PERIOD:


AVG. WIND SPEED:

4.09 m/s

DISPLAY:


6/1/2011

9/30/2011

1/18/2015


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3. October to November (post monsoon season)


WIND ROSE PLOT:

Wind rose diagram - post monsoon season

COMMENTS:

MODELER:


DATE:

1/18/2012

PROJECT NO.:

NORTH

SOUTH

WEST EAST

4%

8%

12%

16%

20%

WIND SPEED

(m/s)

>= 11.1

8.8 - 11.1

5.7 - 8.8

3.6 - 5.7

2.1 - 3.6

0.5 - 2.1

Calms: 3.76%

TOTAL COUNT:

1464 hrs.

CALM WINDS:

3.76%

DATA PERIOD:


AVG. WIND SPEED:

3.26 m/s

DISPLAY:


10/1/2011

11/30/2011

1/18/2015


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4. December to February (winter season)


WIND ROSE PLOT:

Wind rose diagram - winter season

COMMENTS:

MODELER:


DATE:

1/18/2012

PROJECT NO.:

NORTH

SOUTH

WEST EAST

5%

10%

15%

20%

25%

WIND SPEED

(m/s)

>= 11.1

8.8 - 11.1

5.7 - 8.8

3.6 - 5.7

2.1 - 3.6

0.5 - 2.1

Calms: 2.73%

TOTAL COUNT:

2160 hrs.

CALM WINDS:

2.73%

DATA PERIOD:


AVG. WIND SPEED:

3.21 m/s

DISPLAY:


1/1/2011

12/31/2011 -

1/18/2015


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4.6.6 Inversion height

The maximum inversion heights at the project site during the day time & night time for all the months of the year is as given in the table 4.3. The maximum

mixing height of 4000 m is observed during the month of June during the night time and 3319 m during the month of May during the day time. The minimum inversion heights are 1756 m in the month of December during the day and

1786 m during the night in the month of February. 4.6.7 Cloud cover

The minimum cover measured in the unit of tenths is 2 during most of the

months. The maximum observed cloud cover is 10 during the months of January, June to December.

4.7 SOCIAL INFRASTRUCTURE AVAILABLE

Infrastructure is the basic physical and organizational structures needed for the operation of a society or enterprise or the services and facilities necessary for an economy to function.

The term typically refers to the technical structures that support a society, such as roads, water supply, sewers, electrical grids, telecommunications and

so forth and can be defined as "the physical components of interrelated systems providing commodities and services essential to enable, sustain, or

enhance societal living conditions. Viewed functionally, infrastructure facilitates the production of goods and

services, and also the distribution of finished products to markets, as well as basic social services such as schools and hospitals; for example, roads enable the transport of raw materials to a factory.


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The list of hospitals & other infrastructural facilities available in the vicinity of the proposed industry is tabulated below

Table 4.4: List of health-care facilities in the surroundings

Sl. No.

Hospital Distance

Direction w.r.t. the industry

1 Narayana Multi Speciality Hospital

8 km North west

2 Vijayasree Hospital 11 km West

3 Sparsh Hospital 5 km South East

Note: All distances mentioned are aerial.


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CHAPTER 5

PLANNING BRIEF

5.1 PLANNING CONCEPT

M/s. Somu chemicals and pharmaceutical Pvt. Ltd., is an herbal extract and

Active Pharmaceutical Ingredients (APIs), Intermediates manufacturing industry with R & D activity.

5.2 POPULATION PROJECTION

Maximum workforce employed during peak construction period: 25 people Total no. of people proposed to be employed during operation phase: 40 people

5.3 LAND-USE PLANNING

The industry is designed envisaging adequate area for landscape, process section and utilities, storage areas for raw materials, finished products and internal movement of vehicles as shown in the table below.

Table 5.1: Land-use pattern

Sl. No.

Particulars Area (Sq ft)

1 Total plot area 10,000 (100 %)

2 Hard paved area 2000 (20 %)

3 Landscape/Green-belt area

3000 (30 %)

4 Ground coverage area 5000 (50 %)

5 Built-up area 7,000

The site area details are shown in the plot area drawing appended. 5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND

“M/s. Somu Pharmaceutical Pvt. Ltd.,” is basically an Active Pharmaceutical

Ingredients (APIs) and Intermediates manufacturing industry with R & D activity.

The infrastructure demand for the project is detailed in the following sections 5.4.1 Roadways

Roadways are required for

transportation of materials & workers during construction phase &


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transportation of employees to & from the industry during the operation phase.

The major roadways in the vicinity of the project site are shown in section 4.1, Chapter 4

5.4.2 Water supply & sewerage infrastructure Water demand for the industry will be met by Bore well.

The domestic sewage generated will be treated in septic tank and soak pit.

The industrial wastewater generated from the project will be treated in Common Effluent treatment Plant (CETP)


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CHAPTER 6

PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA):

M/s. Somu chemical & pharmaceutical Pvt. Ltd., is an Active Pharmaceutical Ingredients (APIs), Intermediates manufacturing industry with R&D activity.

6.2 GREEN-BELT

An area of 3,000 sq ft (i.e. 30 % of the total plot area) is reserved exclusively for green-belt/landscape development.

About 50 trees of various native/indigenous variety are proposed to be planted.

6.3 SOCIAL INFRASTRUCTURE Detailed in Chapter 4, Section 4.8.

6.4 CONNECTIVITY

Detailed in Chapter 4, Section 4.1.

6.5 DRINKING WATER MANAGEMENT The source of water supply for the industry is Bore well. The total water

requirement is about 12 KLD. 6.6 SEWERAGE SYSTEM

At present the industry does not have the common Underground drainage

system (UGD) facility. The domestic sewage generated from the project is treated in septic tank & soak pit.

6.7 INDUSTRIAL WASTE MANAGEMENT

The industrial wastewater is sent to be Common Effluent Treatment Plant For the treatment.

6.8 SOLID WASTE MANAGEMENT The domestic garbage is proposed to be composted within the industry

premises & the product will be used as manure for green-belt/landscape development.


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The hazardous solid wastes generated will be stored at hazardous waste

storage area and sent to cement industries for co-incineration (as an auxiliary fuel) during the manufacture of cement or returned to the vendors for recharge

& re-use. 6.9 POWER REQUIREMENT & SUPPLY SOURCE

The total power requirement of the industry is 65 kVA which will be sourced from BESCOM. Further one diesel generator of 63.5 kVA capacity is proposed

to be installed to serve as an alternative source of power supply to this unit.

CHAPTER 7

REHABILITATION & RESETTLEMENT PLAN

M/s. Somu chemicals and pharmacauticals Pvt. Ltd., is coming up in a

designated industrial area. No home outstees/land outstees are expected & hence no rehabilitation plan is envisaged.


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CHAPTER 8

PROJECT SCHEDULE & COST ESTIMATES

8.1 TIME SCHEDULE The time schedule for completion of the proposed project is given in the

following table

Particulars Time schedule

Start of construction activity

Existing plant

Completion April, 2016

8.2 ESTIMATED PROJECT COST

Total capital investment on the proposed Project is detailed as under

Sl No

Particulars Cost of the project in Rs (Lakh)

1. Land & Building

144.00

3. Plant & machinery 182.00

4. Office equipment 3.00

5. Furniture & fixtures 10.00

6. Environment Management Budget

3

Grand total 342.00


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CHAPTER – 9

ANALYSIS OF PROPOSAL

Observing the demographic pattern of the study area it can be inferred that occupational pattern is a mixture more of agriculture rather industrial. The proposed project will increase the employment potential by creating direct and

in-direct employment opportunities and thus be beneficial for the local and near by populace

The management of the industry proposes to give preference to local people with both direct and indirect employment.

MATERIAL SAFETY DATA SHEETS (MSDS)

The MSDS of the below listed chemicals are enclosed

1. Toulene 2. Hexane 3. Acetone

4. Piperdine 5. Benzyl chloride 6. Dimethylamine

7. Formaldehyde 8. Hydrochloric acid

9. Mesitylene 10. Sulphuric Acid 11. Ethyl Acetate

12. Isopropyl alcohol 13. Napthalene 14. Acetonitrile

15. Iodine

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