Pre-Feasibility Report Kumar Organic Products Limitedenvironmentclearance.nic.in/writereaddata/FormB/TOR/PFR/27_Apr... · Pre-Feasibility Report Kumar Organic Products Limited 1

Pre-Feasibility Report Kumar Organic Products Limited

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TABLE OF CONTENTS

1. EXECUTIVE SUMMARY ................................................................................................................... 4

2. INTRODUCTION OF THE PROJECT ................................................................................................ 7

2.1 About the project proponent .................................................................................................................. 7

2.2 About the project ................................................................................................................................... 7

3. PROJECT DESCRIPTION ................................................................................................................. 11

3.1 Type of Project .................................................................................................................................... 11

3.2 Project Location .................................................................................................................................. 11

3.3 Major products of the company........................................................................................................... 14

3.4 Details of alternate sites ...................................................................................................................... 14

3.5 Size of Operation ................................................................................................................................. 15

3.6 Project Description .............................................................................................................................. 16

3.7 Raw Material Required ....................................................................................................................... 28

3.8 Resource optimization/recycling and reuse ......................................................................................... 29

3.9 Power and fuels ................................................................................................................................... 29

3.10 Manpower ........................................................................................................................................... 30

3.11 WATER REQUIREMENT ................................................................................................................. 30

3.12 Utilities ................................................................................................................................................ 31

3.13 Liquid waste management ................................................................................................................... 32

3.14 Air pollution control measures ............................................................................................................ 34

3.15 Hazardous and solid waste management ............................................................................................. 34

4. SITE ANALYSIS ................................................................................................................................ 36

4.1 Connectivity ........................................................................................................................................ 36

4.2 Landform, Landuse, Landownership................................................................................................... 36

4.4 Existing Land use pattern .................................................................................................................... 37

4.5. Existing Infrastructure: ........................................................................................................................... 37

4.6. Soil Classification: .................................................................................................................................. 39

4.7. Climatic data from secondary sources: ................................................................................................... 39

4.8. Social Infrastructure available: ............................................................................................................... 39

5.1. Planning concept ..................................................................................................................................... 41

5.2. Population Projection .............................................................................................................................. 41

5.3. Land use planning ................................................................................................................................... 41

5.4. Assessment of Infrastructure Demand .................................................................................................... 42


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5.5. Amenities/Facilities ................................................................................................................................ 42

6 PROPOSED INFRASTRUCTURE .................................................................................................... 43

6.1. Industrial Area: ....................................................................................................................................... 43

6.2. Residential Area ...................................................................................................................................... 43

6.3. Green belt ................................................................................................................................................ 43

6.4. Social Infrastructure ................................................................................................................................ 44

6.5. Connectivity ............................................................................................................................................ 44

6.6. Drinking Water Management.................................................................................................................. 44

6.7. Sewerage system ..................................................................................................................................... 44

6.8. Industrial waste management .................................................................................................................. 44

6.9. Solid waste management ......................................................................................................................... 46

6.10. Power Requirements and Supply/ Source ............................................................................................. 46

7 REHABILITATION AND RESETTLEMENT (R & R) PLAN ........................................................ 48

7.1. Policy to be adopted (Central/ State) ...................................................................................................... 48

8 PROJECT SCHEDULE AND COST ESTIMATE ............................................................................. 49

8.1. Likely date of start of construction and likely date of completion.......................................................... 49

8.2. Estimated project cost ............................................................................................................................. 49

9 ANALYSIS OF PROPOSAL .............................................................................................................. 50

9.1. Financial and social benefits ............................................................................................................... 50

10 CONCLUSION ...................................................................................... Error! Bookmark not defined.

LIST OF TABLES

Table 2.1 Existing products and capacity…………………………………………………….……….10

Table 2.2 Proposed products and capacity……………………………………………………..……..10

Table 3.1 The environmental setting of the existing site…………………………………………..…17

Table 3.2 Raw Material Required………………………………………………………………….…30

Table 3.3 Power and fuel requirement………………………………………………………………..32

Table 3.4 Manpower for existing and proposed units……………………………………………….32

Table 3.5 Water requirement………………………………………………………..………………..33

Table 3.6 List of Utilities………………………………………………………………….….………33

Table 3.7 Liquid waste detail…………………………………………………………………………34

Table 3.8 Hazardous waste…………………………………………………………..……………….37

Table 3.9 Municipal Solid Waste details…………………………………..…………………………37

Table 4.1The details of sensitive areas from the site boundary………………………………..…….39

Table 4.2 Existing infrastructure within 10 Km radius from the site………….……………………..41

Table 4.3 Project surrounding features……………………………………………………………....42

Table 5.1 Area details of the facility……………………………………………………………….…43

Table 6.1 Proposed land use planning……….……………………………………………………….44


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Table 6.1 Solid waste details………………………………………………………………………....47

LIST OF FIGURES

Figure 3.1 Project Site ........................................................................................................................... 15

Figure 3.2 10 km Radius around project site ........................................................................................ 16

LIST OF ABBREVIATIONS

KOPL Kumar Organic Products Limited

ETP Effluent Treatment Plant

STP Sewage Treatment Plant

kWh Kilowatt per hour

WHO World Health Organization

ISO International Standard for Organization

API Active Pharmaceutical Ingredients

R&D Research & Development

USFDA Food & Drug Administration (USA)

KRC Kumar Research Centre

PO Pure Oil

List of annexure

a. Process description and process flow of products – Annexure-1

b. Permission from KSPCB for co processing of Hazardous waste – Annexure 2

c. Agreement for Hazardous waste disposal – Annexure-3 & 4

d. Hazardous Waste Authorization from KSPCB – Annexure-5

e. STP Process flow – Annexure-6

f. ETP Layout – Annexure- 7

g. Agreement for water supply – Annexure-8

h. Existing CFE-Annexure -9.

i. Plant layout of proposed facility - Annexure -10.

j. MSDS of raw materials and products – Annexure -11


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1. EXECUTIVE SUMMARY

S.No. Particulars Details

1. Name of Company Kumar Organic Products limited

2. Location

Existing :---Plot No. 36A/B, 60, 62, 63, 64 and 65, Jigani

Industrial Area, Anekal Taluk, Bangalore

Proposed:-- Plot 83( P), 84 adjacent to existing site separated by

Road no -6

3.

Project Activity,

Category as per

amendments

Project schedule 5(f)- Synthetic Organic Chemicals,

Category B.

4. Name of the project Manufacturing of Cosmaceutical, Active Pharmaceuticals and

Specialty Chemicals

5. Total Land area 40468 m2

6. Existing built up area 28328 m2

7. Proposed additional

built up area 8093 m2

8. Total built up area 36421 m2

9. Proposed product with

capacity

Total 3000 MTPA

1. Zinc Citrate

2. Zinc Phosphate

3. Zinc Lactate

10. Raw material Details as chapter 3, section no. 3.7, Table no. 3.2

11. Fresh water

requirement

Water Consumption: 165 KL/day, Sourced from KIADB and

private water supply will be used.

(165 existing + 35 proposed)

Break up as follows:

S.

No

Water

requirement

KLD

1. Process 80

2. Washing 6

3. Boiler Feed 61

4. Chiller 5.5

5. Domestic 12.5

6. Other utilities 13

7. Green belt 22

Total 200

12. Waste water and Effluent shall be treated in existing system and proposed ETP.


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mode of disposal Treated effluent shall be recycled/reused to the extent and

remaining shall be disposed on land for gardening within

premises.

There will be no discharge of effluent outside factory premises;

The unit shall be zero liquid discharge.

13. Power Existing requirement 500 kwh and after expansion 600 kwh

(from BESCOM).

Existing emergency, DG sets of 1390(640+250+250+125+125)

KVA are insufficient for expansion, hence 1 no. additional DG

(450 KVA) is proposed.

14. Manpower Existing 260 Nos + proposed addition of 30 Nos.

15. Solid and hazardous

waste

Refer chapter 3, section 3.15, pg 36

16. Project cost (estimate) 7.5 Crores

Kumar Organic Products Limited (KOPL), established in 1993, is a privately owned and

professionally managed enterprise with its Head office in Jayanagar Bangalore and two multipurpose

manufacturing sites at Jigani Industrial Area, Anekal Taluk, Bangalore in India, both successfully

inspected by US-FDA facility in 2011and 2014 . It is also approved by COFEPRIS (Ministry of

Health Mexico). Both the plants are also certified by WHO GMP, ISO 9001:2008, 14001:2004 and

have been audited by several Innovators and leading Generic companies from time to time and

export their products in 75 countries to meet the requirement of personal care, Skin care , health care

as well biotech industries

KOPL provides innovative & integrated API solutions with its decades of experience and skill in the

development of novel chemical processes catering to the health care , personal care ,skin care

industries. Our continuous investment in research and development generates a steady flow of APIs

enabling timely introduction of new products in the market.

Our focus is on niche products; with a presence in more than 75 countries. Our partners are

essentially, Personal care, Health care , skin care , companies across the globe for whom we develop

a range of new niche ingredients developed in our own R&D in select \categories like Antibacterial,

Cosmaceutical and few others specialty chemicals.

KOPL has special expertise in Antibacterial and Cosmaceutical products.

A perfect blend of Human talent, R&D Labs, Pilot Plant & cGMP manufacturing facilities backed by

our Quality Assurance, Regulatory Affairs and Intellectual Property cell gives KOPL an edge.


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Our regulatory team is well trained & experienced to comply with US-FDA, EDQM & other

regulatory authority requirements. The company has over10 regulatory filings across the globe for its

APIs to its credit with an impressive pipeline.

KOPL is an existing Company having its unit located at Plot No. 36/62/63/64/60/65/36 Jigani

Industrial Area, Anekal Taluk, Bangalore, developed by KIADB, Bulk Drugs / APIs and specialty

chemicals for various Pharmaceuticals, Cosmaceutical and special chemicals Industries.

Now, the Company proposes to manufacture additional new products at adjacent site to our Existing

units Separated by Road no 6 in Plot no. 83P and 84as APIs the site used for Personal care and skin

care industries


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2. INTRODUCTION OF THE PROJECT

2.1 About the project proponent

Kumar Organic Product Limited is manufacturing various Cosmaceutical, Active Pharmaceuticals

and Specialty compounds. Kumar Organic Products Limited is having ISO certification for ISO 9001

and 14001 since 2004 and USFDA certified facility for exiting products.

Plot no. Activities Specification

36A/B Research & Development of new molecules, Biotech Pilot plant, R&D

Pilot plant

existing

62&63 Manufacturing and storage of materials existing

60&65 Manufacturing and storage of materials existing

64 Utility section, admin and quality control existing

83P/84 Expansion for the manufacturing of Cosmaceutical, APIs and Specialty

Chemicals

Proposed

The main ingredients Triclosan produced throughout for the year 2014-2015 was 1000 metric tons

(MT). The company’s turnover for the year 2014-2015 was Rs. 210.82 Crores and the Profit after

Tax was Rs. 35.7 Crores.

2.2 About the project

KOPL manufactures various products at its manufacturing sites in Bangalore. At present, 8 products

are manufactured amounting to a total of 1940 MT/annum. The existing plant produces the following

products of respective quantities as given in Table 2.1:


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Table 2.1 Existing products and capacity

S. No Existing Products Quantity (Mt/Annum)

1. Triclosan 1200

2. Minoxidil 60

3. 4-Hexyl resorcinol 40

4. CiclopiroxOlamine 20

5. PiroctoneOlamine 60

6. 6-pyrrolidino 2,4-diaminopyrimidine 3-oxide 20

7. 6-pyrrolidino 2,4-diaminopyrimidine 3-oxide, monohydrate 20

8. n-Butyl Resorcinol 20

9. Ethyl hexyl glycerin 500

10. Benzethonium Chloride Under Development

11. Ammonium Thioglycolate Under Development

12. Lauryl lactyl lactate Under Development

13. Steryl heptonate/Octonate Under Development

14. Copper Pyrithione aggregate Under Development

15. Lauryl lactate Under Development

16. Calcium Thioglycolate Under Development

17. Myristyl myristate-– Biotech Under Development

18. Decyl Oleate - Biotech Under Development

19. Radish Ferment extract - Biotech Under Development

KOPL proposes to increase their products by including Zinc Phosphate, Zinc Citrate, Zinc Lactate.

The capacity of the proposed expansion will be 3000 MT/annum. The list of products andtheir

respective capacities given in Table 2.2:

Table 2.2 Proposed products and capacity

S. No Proposed Products Capacity (Mt/Annum)

1. Zinc Citrate 600

2. Zinc Phosphate or Ethyle Hexyle Glycerine 600

3. Zinc Lactate 1800

There is an existing CFE for the products given in Table 2.1 which is attached in Annexure 9.


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2.3 Need for the project

India with its large talented manpower, cost effective chemical synthesis, legal & financial

framework is poised to become sourcing destination of bulk Cosmetical APIs used to the global

market in personal care , health care and skin care industries.

The project is benefitted to fulfill domestic and exports requirements for the manufacturing of

various cosmetics, antibacterial soaps, and emollients, anti ageing creams, lotions, creams and gels

without affecting environmental conditions of the area.

The pharmaceutical industry in India ranks third in the world in terms of volume and contributes

10% to the global pharmaceutical production. According to the Department of Pharmaceuticals, the

Indian pharmaceutical industry is pegged at Rs 810 bn, which includes domestic sales and exports.

The industry is the fourteenth-largest in the world in terms of value and accounted for 1.5% of the

global pharmaceutical market. The industry has a lower share in the global market because Indian

products are available at a price that is 5-50% lower than that in the developed countries. According

to the Department of Pharmaceuticals, the sector employs about 340,000 persons and an estimated

400,000 doctors and 300,000 chemists are serving its 1 bn-plus market.

There will be very good opportunity of employment generation of additional qualified staff &

unqualified workers directly for 100 nos. and indirectly for 50 nos. due to the proposed expansion

project.

2.4 Demand and supply gap

Based on market survey the selected molecules for manufacture have potential for export as well as domestic

market.

2.5 Imports v/s. Indigenous production

To ensure the quality of product and control of manufacturing under current good manufacturing

conditions, it is preferred to have the manufacture done in- house by procuring basic raw materials.

M/s Kumar Organic Products Pvt. Ltd., has reasonably sound base to overcome the technological

barrier to meet the challenges of the industry. The demand for API’s and drug intermediates is on

increase, and the industry is poised for substantial growth in the coming years.

2.6 Export possibility

Products are being exported to various countries from the existing sites and products from the proposed

expansion also shall be distributed across the globe as per the customer requirements

2.7 Domestic / Export Markets

Over 60 per cent of India’s bulk drug production is exported. India’s pharmaceutical exports are to

the tune of Rs 87 billion, of which formulations contribute nearly 55 per cent and the rest 45 per cent

comes from bulk drugs.


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In financial year 2005, exports grew by 21 per cent. The Indian pharmaceutical market has been

forecasted to grow to as much as US$ 25 billion by 2010 as per Organization of Pharmaceutical

Producers of India (OPPI) estimates. However, Espicom’s market projections forecast more modest

but stable annual market growth of around 7.2 per cent, putting the market at US$ 11.6 billion by

2009.

Domestic pharmaceutical exports, growing at 30 per cent per annum, touched a new height of

US$4.8 billion in the financial year 2006-07. The Year’s exports will push the drug sectors

contribution to India’s Forex earnings to 7.75 per cent from the current 5 per cent.

The geographical distribution of various products distributed from the existing facility is detailed as

below.

2.8 Employment Generation (Direct and Indirect)

There will be very good opportunity of employment generation of additional qualified staff &

unqualified workers directly for 100 nos. and indirectly for 50 nos. due to the proposed expansion

project. At present the numbers of employees are 260 nos.

EUROPE &

AFRICA

21%

ASIA

13%

LATIN

AMERICA

13%

NORTH

AMERICA

16%

INDIA

37%


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3. PROJECT DESCRIPTION

3.1 Type of Project

To cater the needs of the market, it is proposed to change the product mix at its existing unit at Plot

No. 36, 63,63,64,60 and 65, Jigani Industrial Area, Anekal Taluk, Bangalore. The proposed project

falls under Category ‘B’, schedule 5 (f) as per the EIA notification dated September 14, 2006 and its

amendments. There are no interlinked projects.

3.2 Project Location

The plot of land acquired from the Karnataka State Industrial Area Development Board (KIADB)

lies in a notified industrial area. The site is located in Jigani village at Latitude12°46’3.17”N,

Longitude 77°38’30.55”E, approximately 10 km from the National highway. Number of other

industries exists nearby such as Hikal Ltd., OTIS, KTTM etc. The layout of the site with existing

facilities is given as below, while proposed expansion layout is enclosed as Annexure 10. The

project location is given in Figure 3.1 and the 10 km radius map from project site is given in Figure

3.2. The 5 Km and 10 Km radius map from the project is given below.


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Site layout plan of existing facilities

The existing facility is located in different plots as below

Status Plot no Activities

Existing 36A/B Research & Development of new molecules

Existing 62&63 Manufacturing and storage of materials

Existing 60&65 Manufacturing and storage of materials

Existing 64 Utility section, admin and quality control

Proposed 83P & 84 For the manufacturing of zinc derivatives


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The proposed project is located at Jigani Industrial Area, AnekalTaluk, Bangalore,and Karnataka.

The site is located about 40 km away from Bangalore Town and it is in the express highway and the

nearest railway station is Anekal railway station (12 km).

Figure 3.1Project Site


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Figure 3.2 10 km Radius around project site

3.3 Major products of the company

The details of current existing major products are given below:

Triclosan: Triclosan is an antibacterial agent and itis manufactured at plot no. 62, 60 and 65,

approximately 1000 mt annually.

Ethyl Hexyl Glycerine : EHG is also used as an antibacterial and it is manufactured at plot no. 64,

60 and 65, approximately 600 mt annually.

Zinc derivatives: Proposed expansion for the manufacturing of Zinc derivatives at plt no. 83P and

84 is approximately 3600 MT annually.

3.4 Details of alternate sites

Since the existing site is only used for the proposed project, the alternate site option is not explored. The

environmental setting of the existing site is given in Table 3.1:


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Table 3.1Environmental setting of the existing site

S. No. Particulars Details

1 Plant site latitude 12°46’3.17”N

2 Plant site longitude 77°38’30.55”E

3 Temperature Max. 34 oC, Min. 21.4

oC

4 Present land use Industrial area

5 Nearest Highway Bangalore Chennai road -10 Km N

6 Nearest railway Station Anekal railway – 12 Kms S

7 Nearest Airport Kempegowda, Bangalore - 65 Kms

8 Nearest village Jigani -3 Kms

9 Nearest major city Bangalore - 25 Kms N

10 Nearest river Nil

11 Type of soil Reddish brown clay silt soil

3.5 Size of Operation

In the view of fulfilling market requirement, we are proposing to change the product mix, presently

we are manufacturing regularly 9 Nos. products and 3 new products will be included with increase in

the production quantity of 3000 MT/annum (existing 1940 + 3000 = 4940 MT/annum).


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3.6 Project Description

Receive Raw Material

Dispensing Raw Material

Raw Materials Charging in Reactor and Reaction monitoring

Centrifuge operation

Material Drying Operation in Dryer

Milling Operation

Sifting

Operatio

n

Blending

Operation

Finished Goods/ Product packing

Finished Goods/ Product Dispatching


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Process detail (Annexure 1)

1. Triclosan:

Synthetic scheme:

Process: 2,4-DCP is reacted with 2,5-DCNB gives amino ether, which is reduced to produce

hydroxy ether, which is purified and extracted to get crude Triclosan. Crude Triclosan is

distillated for Triclosan Pure oil, which is crystallized, centrifuged following drying and

sieving.

Process Flow chart:

CONDENSATION REACTION.

DCP

DCNB

KOH

TCE

EXTRACTION

WATER WASHING

REDUCTION

Solvent recovery

Amine Isolation

CIP

water 100 lit)

TCE

NaOH

Water

AE

TCE

TCE

TCE

Vaccum

NE + TCE layer

Alkaline water layer

Alkaline water layer

(To ETP)

Extracted NE +

TCE layer

Extracted & water washed NE +

TCE laye

AE + TCE

Spent iron powder Filtered AE + TCE

NaNO2


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NITROSYL PREPARATION

DIAZO PREPARATION

HYDROLYSIS PREPARATION

EXTRACTION

NEUTRALISATOIN & WATER WASHING

CO Isolation

Water

NaOH TCE

AE Water

CO

TCE

TCE

TCE MLR

TCE


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DISTILLATION

CRYSTALLISATION

2. Minoxidil:

Synthesis process: N-Oxide (2,4-Dichloropyrimidine) is treated with Piperidine to get

Minoxidil crude, which gives Minoxidil by crystallization. The crystallized product is

centrifuged, dried and micronized to get Minoxidil powder

High Vaccum Distillation

TCE

FF

CO High Vaccum

Residue PO

Crystallizer

Hexane MLR

Hexane PO

Centrifuge

Drier

Sifter

TCS wet wt.

TCS + Hexane MLR

Hexane recovery

Hexane

Hexane residue

(for reprocess)

TCS blended qty

Lumps

Blending

TCS

Dry TCS


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Process Flow chart

Stage 1: Manufacturing of

crude:

Stage 2:

Purification

3. Kopexil :

Synthesis process: N-Oxide gives Kopexil by hydrogenation. The crystallized product is

centrifuged, dried and micronized to get Kopexil powder

MIINOXIDIL (CRUDE)

MINOXIDIL

Methanol

Activated Charcoal

2,4-Diamino-6-chloropyrimidine-3-oxide

MINOXIDIL (CRUDE)

Piperidine Condensation

Methanol


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Process flow chart

4. Kopyrrol:

Synthesis process: N-Oxide gives Kopyrrol by reaction with pyrrolidine. The crystallized

product is centrifuged, dried and micronized to get Kopyrrol powder

Process flow diagram

N-Oxide ( 2,4-Diamino 6-

chloropyrimidine)

KOPEXIL

(Cosmetic ingredients)

Not listed in pharmacopeia

Hydrogenation


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5. 4-Hexyl Resorcinol:

Synthesis process: Hexanoic acid reacts with Resorcinol in presence of activated zinc to give

crude products. Which gives finished product following distillation, crystallization,

centrifugation, drying steps

6. PiroctoneOlamine:

Synthesis process: Di methyl acrylic ester is prepared with reaction of 33-dimethyl acrylic

acid and hydroquinone by esterification, which is then converted to pyrone. Pyrone is

distilled following crystallization, centrifugation and drying operations to get desired finished

product.



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7. CiclopiroxOlamine:

Synthesis prodcess: Pyrone is treated with hydroxylamine salt in presence of acetic acid,

solvents and water. The output reaction mass is treated with monoethanolamine to get

Ciclopirox crude

Process flow diagram:

Synthesis of 3,3-dimethyl acrylic ester

Condensation of 3,3-dimethyl acrylate and

3,5,5-trimethyl hexanoyl chloride

Synthesis of 2-pyrone

Synthesis of oxime

Preparation of Kopirox( piroctone olamine)


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Residue (Oxime)

Finished product


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8. N-butyl resorcinol:

Synthesis process: Resorcinol converted to Butyryl resorcinol by condensing Butyric

acid with Resorcinol and reducing the resulting Ketone using a Zinc and Hydrochloric

acid.


Butyric acid

Condensation

9. Ethyl hecyl glycerin:

Synthesis process: 2-Ethyl hexanol is condensed with Allyl chloride in presence of alkali to

give Allyl ethyl hexylether. This on treatment with Hydrogen peroxide and Formic acid ,

yields the formate esters. This on transesterification with Methanol in presence of an acid ,

yields KOPCERIN.

Process flow diagram:

Resorcinol

4-n-Butylresorcinol

2,4-Dihydroxybutyrophenone

Reduction


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10. Zinc Citrate

Synthesis process: Citric acid reacts with zinc oxide gives zinc citrate.


Distilled water 2.60 ltr

Citric acid mono hydrate (387 g) Zinc oxide (10 g X 22 times + 5 g)

1.3 ltr x 2 times water

Zinc oxide 2.7g

5 Lt Beaker

Stir at 30C for 3 hrs

Cool to 30C & Filter the

precipitate

Stir

Water for ETP

Solid product (wash)

Heat at 70 to 75C for 3 hrs

Reaction mass at 30C

Alkali

@ 35C Reactor

2-Ethylhexanol

Epichlorohydrin

chloride

Water

Reactor

(Liquid)

Reactor

(Liquid)

HVD

KOPCERIN HVD

Product analyzed for

KOPCERIN

H2SO4

HVD

Formic

acid(85%

)

Acid

Methanol


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11. Zinc Lactate

Synthesis process: Lactic acid gives zinc lactate after the reaction with zinc oxide.


H2O

Lactic acid(88%)

Zinc Oxide

12. Zinc Phosphate

Synthesis Process: Phosphoric acid reacts with zinc oxide and gives zinc phosphate.


H2O

Phosphoric acid

Drying

Lactic acid &Water

Filtration

1 ltr 3-neck RBF

Filter

Dry

Water for ETP

Product : 518 - 520g

KOPCITRATE.Zn(TH)

(Zinc citrate trihydrate)


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Zinc Oxide

3.7 Raw Material Required

Raw Materials required with approximate quantity for Proposed Change of Product Mix is given inTable 3.2.

Table 3.2 Raw Material List

S. No. Name of raw material Quantity

(MT/Year)

Proposed

1. 2,4-DCP 1320 --

2. 2,5-DCNB 1536 --

3. Sulphuric acid 7200 --

4. HCl 1200 --

5. Iron powder 1380 --

6. Hexane 300 --

7. Ethyl Acetate 60 --

8. Methanol 120 --

9. Hexanoic acid 60 --

Drying

Lactic acid &Water

Filtration

1 ltr 3-neck RBF


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S. No. Name of raw material Quantity

(MT/Year)

Proposed

10. Acetic acid 27.6 --

11. Resorcinol 60 --

12. Mono ethanol Amine 10 --

13. Butyric acid 20 --

14. Di-methylic acrylic acid 60 --

15. Ethyl Hexanol 500 --

16. Piperidine 100 --

17. 2,4-6-aminochloropyridine 100 --

18. Zinc oxide -- 1914

19. Citric acid -- 420

20. Lactic acid -- 3186

21. phosphoric acid -- 384

Raw materials would be obtained by road transportation through different parts of the country such as

Chennai, Maharashtra, and Gujarat as well as can be imported also. The finished goods for domestic sales

would be by road and for export shall be by air.

3.8 Resource optimization/recycling and reuse

After the reaction is complete the solvents are recovered, tested as per pre-defined specification. The residue

from the solvent recovery is sold out by KSPCB approved vendors for disposal. The recovered solvents are

collected in drums, labeled and analyzed. Then they are reused (recycled) for the process, mostly for the same

product.

3.9 Power and fuels

The existing power requirement is 500 kWh and with the proposed expansion additional power

required is 600 kWh. This is a combination of HT and LT loads. The power required will be sourced

from BESCOM.

As the existing boiler (heater) is adequate for the revamp conditions, the fuel oil and fuel gas

requirements will not vary when compared to the existing conditions. There are three DG sets are

used as an alternate source of power if required for the existing sites, while proposed expansion site


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will also equipped with a dedicated DG set for the site. The details of power and fuel requirements

are given in table 3.3:

Table 3.3 Power and fuel requirement

Details Capacity Source

Existing After

ProposedExpansion

Power Requirement 500kwh 600kwh BESCOM

Diesel Requirements Approx.5000

lit/Month

Approx. 6000 lit/Month HP

Fuel oil 18 Kl/Month 20 Kl/Month Furnace Oil

3.10 Manpower

The existing Bangalore Units have a total of 262employees including 38 contract workers. There will

be additional 30 staff required for the proposed expansion, Table 3.4.

Table 3.4Manpower for existing and proposed units

Designation Shift Plot no.

36

Plot

no.

62/63

Plot No.

60/64/65

Plot no.

83P/84

(Proposed)

Manager General Shift 10 10 10 2

Panel Engineers Rotating Shift -- 22 22 5

Shift Engineers Rotating Shift -- 28 28 3

Field Operators Rotating Shift 38 28 28 15

Contract workers (House

Keeping) General Shift 14 12 12 5

Total Manpower 62 100 100 30

3.11 WATER REQUIREMENT

The total requirement of raw water for the existing unit is 165 KLD/day. The water requirement is

met mainly by the water from KIADB and private water suppliers to the desalination plant and

effluent recycling units. There is no bore well source inside the Plant premises.

After the proposed expansion, additional water requirement will be slightly envisaged, as the utilities

required for manufacturing of new products, Table 3.5.


31

Table 3.5 Water requirement (Existing 165 KLD + 35 KLD for expansion)

S.

No Water requirement

Existing

(KLD)

Proposed

(KLD)

Break-up

Fresh water Treated

Water Total

8. Process 60 20 20 60 80

9. Washing 5 1 1.2 4.8 6

10. Boiler Feed 60 1 21 40 61

11. Chiller 5 0.5 5.5 - 5.5

12. Domestic 10 2.5 12.5 - 12.5

13. Other utilities 10 3 13 - 13

14. Green belt 15 7 22 - 22

Total 165 35 95.2 104.8 200

3.12 Utilities

Table 3.6shows the list of utilities in the project:

Table 3.6 List of Utilities

S. No. Utility Existing Flow rate Flow rate after proposed

project

1 VHP Steam 2.7 MT / hr 3.7 MT / hr

2 MP Steam 1 MT / hr 1.5 MT / hr

3 LP Steam 1.7 MT / hr 2.2 MT / hr

4 Nitrogen 10 Nm3 / hr 12 Nm3 / hr

5 Cooling Water 500m3 / hr 700m

3 / hr

6 Service Water Intermittent Requirement Intermittent Requirement

7 Boiler Feed

Water Intermittent Requirement Intermittent Requirement

8 Plant Air Intermittent Requirement Intermittent Requirement

9 Electrical

Power 500 kWh 600 kWh


32

3.13 Liquid waste management

Table 3.7 Liquid waste detail

Units ETP generation -Existing

(KLD)

ETP generation- Purposed (KLD)

Plot No. 36 2 ****

Plot no. 62/63 4.95 ****

Plot No. 60/64/65 8.75 ****

Plot No. 83P/84 **** 3

TOTAL 15.7 3

Total Effluent 18.7

A) ETP Treatment plant


33

B) Sewage Treatment Plant (STP)


34

3.14 Air pollution control measures

1. The discharge of emissions from the additional air pollution source from the premises of the KOPL is

passes through the air pollution control equipment (Scrubbers/Chimney) and discharged through

stack/chimney.

2. Ambient Air quality of the premises conforms to the national ambient air quality standards specified

in environmental (protection) rules.

3. Emissions are analyzed on monthly basis

Below are the details of control of air pollution at the sites:

Air pollutants controls

Details Plot no. 36 Plot no. 62/63 Plot No.

60/64/65

Plot no.

83P/84

(Proposed)

Chimney 1 1 1 1

Scrubber 1 2 2 --

3.15 Hazardous and solid waste management

The hazardous wastes generated from Plant(Table 3.8)are collected, stored and disposed through

authorized disposal cum recycle facilities as per the authorization from PCB and the unit has

agreements with all waste disposal facilities for the same. There is no internal disposal facility

available within the site.The Authorization Letter from KSPCB is enclosed as Annexure 5.

The hazardous waste generated from the existingmanufacturing unit, is Benzofuranand this is

being sent toVasavdatta Cement for co-processing,approved CPCB facility which is located in

Gulberga, Karnataka.

Table 3.8 Hazardous waste

Waste

Category

hazardous waste

Generated

Quantity Method of handling

5.1 Used Oil 1.5 KL Collected in leak proof containers and

disposed only to KSPCB registered

authorized re-processor

28.1 Organic Residue 1012.5 Mt/A Stored in secure manner and handed

over to KSPCB authorized incinerator

33.3 MS Drums 1230 Nos s/A Stored in secure manner and handed

over to KSPCB authorized recycler 34.3 HDPE Used Liners 650 nos/A

34.3 ETP Sludge/Chemical

sludge from clarifier and

evaporator

22.5Mt/A Stored in secure manner and handed

over to KSPCB authorized TSDF


35

The Municipal Solid Waste generated from the site is collected and transported to recyclers,

municipal yards and landfills depending on the type of waste. The details are given below in

table 3.9:

Table 3.9Municipal Solid Waste details

S.

No

Nature of

Solid Waste

Quantity

T/Year

Method of Handling

Collection & Storage Treatment Disposal

1 Paper / Card

Board

2 Separate storage area Nil Burnt in boiler

2 Dust Bin

collections

12 Separate storage area Nil disposal in land

filling through

authorized

vendors

3 Dry leaves

Grass

1 Separate storage area Nil burnt in boiler

4 Metal scrap 12 Separate storage area Nil sold as scrap to

vendors under

agreement

5 Wooden scrap 12 Separate storage area Nil burnt in boiler


36

4. SITE ANALYSIS

4.1 Connectivity

The proposed site on the NH – 4 and is connected to Bangalore –Chennai (NH 7) road just 10.0 Km away

from the Factory entrance.

Nearest railway station is Anekal: 12.0 km and

Kempegowda International Airport: 65

4.2 Landform, Landuse, Landownership

The Plant is located at plot nos.: 36/60/62/63/64/65 and 83P/84, Village, Industrial areaTaluk,Anekal

District-Bangalore, Karnataka. The layout plan of Bangalore Units is enclosed in section no. 3.2,

while proposed plant layout is enclosed as Annexure 10.

4.3 Topography

Bangalore has two unique Topography terrains—North Bangalore Taluk and the South Bangalore

taluk. The North Bangalore taluk is a relatively more level plateau and lies between an average of

839 to 962 meters above sea level. The middle of the taluk has a prominent ridge running NNE-

SSW. The highest point in the city, Doddabettahalli, (962m) is on this ridge. There are gentle slopes

and valleys on either side of this ridge. The low-lying area is marked by a series of water tanks

varying in size from a small pond to those of considerable extent, but all fairly shallow.

The topography of Bangalore is flat except for a central ridge running NNE-SSW. The highest point

is Doddabettahalli, which is 962 m (3,156 ft) and lies on this ridge. No major rivers run through the

city, though the Arkavathi and South Pennar cross paths at the Nandi Hills, 60 km (37 mi.) to the

north. River Vrishabhavathi, a minor tributary of the Arkavathi, arises within the city at

Basavanagudi and flows through the city. The rivers Arkavathi and Vrishabhavathi together carry

much of Bangalore's sewage. A sewerage system, constructed in 1922, covers 215 km² (133 mi²) of

the city and connects with five sewage treatment centers located in the periphery of Bangalore.[5]

The South Bangalore taluk has an uneven landscape with intermingling hills and valleys. The

southern and western portions of the city consist of a topology of granite and gneissic masses. The

eastern portion is a plane, with rare minor undulations.

There are no major rivers flowing through the city. However, rivers Arkavathi and Kaveri merge

within the proximity of Nandi Hills, which lie 60 km north of Bangalore. River Vrishabhavati, a

tributary of Arkavathi, flows for a small stretch in the Bangalore North taluk and carries a bulk of the

city's sewerage. The city has a handful of freshwater lakes and water tanks such as Madivala tank,

Hebbal tank, Ulsoor lake and Sankey Tank. Groundwater occurs in silty to sandy layers of

alluvialsediments and jointed quartzite.

https://en.wikipedia.org/wiki/Bangalore_geography_and_environment#cite_note-sewage-5


37

The rock types prevalent in the district belong to the Saugar, Charnokite and Peninsular Gneissic

Complex (PGC) groups. The PGC is the dominant group of rocks and covers two-thirds of the area

and includes granites, gneissis and migmatites. The soils in Bangalore vary from red laterite to

clayey soils

Topomap: Annexure 13 (5 km radius map) and Annexure 14 (10 km radius map).

4.4 Existing Land use pattern

The present land use is in the industrial zone. The details of sensitive areas from the site boundary

are given in Table 4.1. The site does not fall within the CRZ area

Table 4.1 Details of sensitive areas

S.No Name Distance & Direction (km)

1. Bangalore-Air Port 60

2. Bangalore-City Railway Station 40

3. Hyderabad 320

4. Tamil nadu (Hosur) 20

5. Anekal Taluk 14

6. Jigani Village 3

7. Bennerghatta national park 8

4.5. Existing Infrastructure:

a. Land

The Plant facilities are spread over 20234Sqm KIADB Land which is completely fortified and protected on all

four sides by boundary walls.

b. Buildings

Total built up area is divided into various sections like Production Blocks, Engineering, Warehouses,

Administration, Canteen, Toilets etc. There is adequate space & provision for operations.

c. Plant Machinery & Utilities

The Plant Facilities have been designed and set up with the objective to carry out almost all chemical

reactions and processes. Details of plant and machinery and utility equipments used for the production are as

below:


38

i.Process Equipments:

Reactors : 50

Centrifuges :7

VTDs : 03

Air Jet Mill: 01

Multi Mill:01

Sifter : 04

Blender : 02

ii. Machinery / Utility Equipments;

Boilers: 3

Cooling towers :5

DG sets : 05

Brine chilling plant:02

Air compressors:04

HVAC system: 2

Vacuum pumps: 10

Scrubbers: 05

iii. Safety Equipments:

Fire Hydrant System : 03

Fire Extinguishers: 400

Fire Alarm System : 03

Eye wash fountain / Safety Showers : 5

Emergency PPE cupboards : 5

Wind Sack : 4

Compressed Air Foam System (CAFS) : 1

FM-200 (Automatic fire extinguishers) : 100

AFT (Advanced Fire Technology) : 5

The site is well connected by road to NH 7 (Bangalore- Chennai). The list of the few existing industries within

10 km from the site is given in Table 4.2.


39

Table 4.2 Existing infrastructure within 10 Km radius from the site

S.No. Name Distance from site (km)

1. Mallik Engineering 0.02

2. J’Pan Tubular Components 0.07

3. OTIS 0.8

4. Kirloskar Toyota textile machinery Pvt.

Ltd.

0.8

5. Hikal Ltd. 0.7

6. Aron Universal Ltd. 0.5

7. Ansell 9.8

8. HCL Technologies 2.2

9. Cipla Limited 1.8

10. Mylan Limited 1.8

4.6. Soil Classification:

The top soil is reddish brown clay silt soil. The soil classification is Laterite soils and is mainly found in

Anekal Taluk.

4.7. Climatic data from secondary sources:

Normal annual rainfall of Bangalore urban district is 831mm. During the year 2005, Bangalore urban district

received actual rainfall of 1342.7 mm in 69 rainy days. Of the total rainfall, contribution from southwestern

monsoon is 54.18% and 26.53% is from northeastern monsoon. In addition to this, Pre-monsoon showers

contribute significant rainfall of 18.53%. The annual average maximum temperature ranges from 23.9 to

30.4°C and minimum temperature ranges from 19.6 to 23.9°C. The annual average humidity is 65.5°C. The

annual average wind speed is 4.5km/h.

4.8. Social Infrastructure available:

The social infrastructure facilities available near the site are given in Table 4.3


40

Table 4.3 Project surrounding features

S.No. Name Km

Schools and Colleges

1. Govt. School Jigani 3.0

2. International Institute of Information Technology 8.33

3. Vivekananda Kendra Vidyalaya 1.3

4. Government School Hennagra 4.5

Religious Places

5. Sri Lakshmi Narashimha Swami Temple 0.1

6. Sri Champakadhaama Temple 12

7. Ayyapa Temple 2

8. Jigani Masjid 2.5

Hospitals

9. YK hospital 0.5

10. Suhas Hospital 1.0

11. Vijayashree Hospital 1.0

12. Narayana Hrudayalaya 10.0

13. Sparsh Hospital 12.0


41

5 PLANNING BRIEF

5.1. Planning concept

The city of Bangalore is easily accessible along the link road and further along the National highway. The

peripheral ring road of BDA is accessible from NH- 7. Nearest railway station is Anekal: 12.0 km and

Kempegowda International Airport: 65 Km.

5.2. Population Projection

262 temporary and permanent employees at existing site and 30 additional manpower is projected.

5.3. Land use planning

The Total site area is 20234 Sq. Mt. The area details of the facility are given below in Table 5.1:

Table 5.1 Area details of the facility

S. No. Description Area

Sq. mt

% of area

Sq. mt

1. Production Block-1 4046 19.99


3. General Utility, General Warehouse, QC, R&D, Conference

Hall & Office area

2023

9.99

4. Cooling Tower 100 0.49

5. Security 10 0.04

6. EHS Office and OHC 10 0.04

7. ETP 2023 9.99

8. Drum Storage yard 1000 4.94

9. Underground Solvent Storage yard 500 2.47

10. Scrap yard 500 2.47

11. Furnace Oil Storage yard 50 0.24

12. Engg Office, Engg Stores, QA Office, Canteen, Change room

and DG

100

0.49

13. Green belt area 1779 8.79

Total Area 20234 100%


42

5.4. Assessment of Infrastructure Demand

The facility is within the KIABD industrial area and the proposed project is only a expansion of existing

facility.

5.5. Amenities/Facilities

The existing site is having Canteen facility for employees, Occupational Health Center (OHC) and assembly

points etc.


43

6 PROPOSED INFRASTRUCTURE

6.1. Industrial Area:

The proposed facility, table 6.1 Proposed land use planning.

S. No. Description Area

Sq. mt

% of area

Sq. mt


2. Production Block-2 00 00

3. General Utility, General Warehouse, QC, R&D, Conference

Hall & Office area

1800

22.34

4. Cooling Tower 20 2.48

5. Security 24 2.97

6. EHS Office and OHC 30 0.37

7. ETP 100 1.24

8. Drum Storage yard 100 1.24

9. Underground Solvent Storage yard 00 00

10. Scrap yard 500 6.20

11. Furnace Oil/Briquett Storage yard 200 2.48

12. Engg Office, Engg Stores, QA Office, Canteen, Change room

and DG

200

2.48

13. Green belt area 4680 58.10

Total Area 8054 100%

6.2. Residential Area

Not Applicable.

6.3. Green belt

The total area of the site is 20234 sq. m. Green belt area of the present facility is 1779 sq.m, (8.79%). The

remaining 24.21% to account for a total of 33% is provided by KIABD.


44

6.4. Social Infrastructure

KIADB Industrial Area.

6.5. Connectivity

Site is well connected by an asphalted road which further connects to Bangalore –Chennai (NH 7) road just

10.0 Km away from the Factory entrance.

Nearest railway station is Anekal: 12.0 km and

Kempegowda International Airport: 65

6.6. Drinking Water Management

Drinking water facility is available and water is purchased from KIADB or local suppliers, which is treated

using the existing water treatment facility for drinking water.

6.7. Sewerage system

The quantity and quality of wastewater in the plant is controlled by following measures:

Sewage water is collected from the plant and treated using STP and used for the gardening at

the site.

6.8. Industrial waste management

a. Air Environment:

i. Sources:

Reactors, Distillation process

Boilers

Fugitive vapours from reactors, centrifuges and at discharges of vessel contents, etc.

D.G. sets

ii. Mitigative measures:

1. All reactors are connected to scrubber with a stack attached.

2. The vapours have been collected through exhaust system consisting of hood, duct which

are connected to scrubbers.

3. Stack of 6m ARL are provided to D.G. sets.

4. Boilers are connected with chimney

5. Use of PPE’s

b. Noise Environment:

i. Sources:


45

Generators

Reactors

Compressors


1. Acoustic barriers or shields to the machineries.

2. Vibration free foundations for machineries

3. Acoustical walls and roofs to the building where such machineries are installed.

4. Segregation of machineries having high noise level in isolated buildings.

5. Proper maintenance of machineries especially oiling and greasing of bearing and gears

etc.

6. Avoiding vibration of machineries with proper design of machineries such as speed,

balancing etc.

7. Use of personnel protective such as earmuff and ear fug for persons working in such

locations.

8. Plantation of green trees around the factory building and premises to control the intensity

of noise to the surrounding area.

9. Use of PPE’s

10.

c. Water Environment:

i. Sources:

Process water

Cooling tower blow down

Washing

Softner Regeneration

Domestic waste water


1. Effluents from the plant is been stored and neutralized in a collection tank and then sent

to Effluent Treatment Plant

2. Domestic water will be treated in Septic tank followed by soak pit.

3. Recycle of process water including steam condensate and reuse of treated wastewater

in the plant

4. Control of water taps, washings, leakages from pump glands and flanged joints.

5. Overflow of vessels is strictly avoided

6. Floor cleaning with water will be replaced with dry cleaning.

d. Solid & Hazardous waste:

i. Sources:


46

Used oil

Spent solvents

Distillation residue

Process residue

Off specification products

Discarded containers (Ex. Barrels, Carboys & liners)


1. Used oil shall be collected in leak proof containers & disposed to Central Pollution

Control Board / Karnataka State Pollution Control Board registered authorized recyclers.

2. Spent solvents will be stored in a secured manner and handed over to Karnataka State

Pollution Control Board authorized recyclers.

3. Distillation residue will be stored in a secured manner and handed over to Karnataka State

Pollution Control Board authorized incinerators.

4. Process residues will be stored in a secured manner and handed over to Karnataka State

Pollution Control Board authorized incinerators.

5. Off specification products will be stored in a secured manner and handed over to KSPCB

authorized incinerator.

6. Discarded containers will be stored in a secured manner and handed over to Karnataka

State Pollution Control Board authorized recycler after washing.

6.9. Solid waste management

Solid wastes generated will be stored and disposed as detailed in the Table 6.2.

Table 6.2 Solid waste

Waste Quantity (kg/day)

Collection method

Disposal method

Organic 2126 Bins Sent to cement industry for co-incineration. Annexure 2.

Inorganic 3945 Bins Authorized dealer Annexure 3.

ETP Sludge 1900 Trolleys Authorised dealer Annexure 4.

6.10. Power Requirements and Supply/ Source

Existing requirement 500 kwh and after expansion 600 kwh (from BESCOM).

Existing emergency, DG sets of 1390 640+250+250+125+125) KVA are insufficient for expansion,

hence 1 no. additional DG (450 KVA) is proposed.


47

DG sets detail: Existing site has equipped with separate DG set as per given detail.

Plot no. Activities Nos Capacity

36 Research & Development of new molecules 1 125 KVA

62&63 Manufacturing and storage of materials 2 125 KVA/250 KVA

60&65 Manufacturing and storage of materials 1 640 KVA

64 Utility section, admin and quality control -- --

83P/84 Proposed for the manufacturing of zinc salts 1 450 KVA


48

7 REHABILITATION AND RESETTLEMENT (R & R) PLAN

7.1. Policy to be adopted (Central/ State)

Not applicable as proposed project only an expansion within the existing unit of KIADB industrial area.


49

8 PROJECT SCHEDULE AND COST ESTIMATE

8.1. Likely date of start of construction and likely date of completion

Propose site civil construction was started in 2014 and shall be completed by July 2016.

8.2. Estimated project cost

The budget for proposed expansion for the manufacturing of zinc salts (Such as Zinc Citrate, Zinc Phosphate

and Zinc Lactate) is approximately 8 crores. Proposed products are safe for the environment as there is no

harmful chemicals shall be used for the manufacturing of the products.


50

9 ANALYSIS OF PROPOSAL

9.1. Financial and social benefits

Annual Turnover: 215 cr

Annual profit: 30 cr

Dividend to share holders: 25%

Social Benefit:

Employment to local community: 40%

CSR benefit to local community:

1). Promoting education-Donated utensils for midday meal, steel almirah, box rack, painting on

walls for Govt primary school ,vadarapalya,jigani.

2). Animal welfare- Adopted 2 Tigress at Mysore Zoo.

3). Promoting education- Shortlisted 15 students for scholarship.

4). Providing safe drinking water-Installing RO machine to Higher primary school,Kaushike

Village at Hassan.

Green belt benefits to the environment.-Done plantation at new plot,Harpanhally plot and nearby

schools at Jigani.

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