Post on 02-Sep-2018
FORM- I & STANDARD TEMPLATE FOR
CAPACITY EXPANSION
APEX DRUGS & INTERMEDIATES LTD SY.NO.10, IDA GADDAPOTHARAM,
JINNARAM (M), MEDAK (D) ANDHRA PRADESH
M/S Pridhvi Enviro Tech pvt. Ltd
Studies & Documentation By
Submitted by M/S APEX DRUGS & INTERMEDIATES LTD, 184/C, Lawn House
(MoE&F O.M – S.NO: 118)
SY.NO 10, GADDAPOTHARAM(V) VengalRao Nagar JINNARAM(M), Hyderabad-500038 MEDAK (D) Ph: 040-40179770 ANDHRA PRADESH Fax: 040-66730926 E-Mail: pvr@pridhvienviro.com
SUBMITTED TO MINISTRY OF ENVIRONMENT & FORESTS, GOI
PARYAVARAN BHAWAN, CGO COMPLEX, LODHI ROAD, NEW DELHI-110003
PRE-FEASIBILITY REPORT
FOR TERMS OF REFERENCES FOR
CAPACITY EXPANSION October, 2013
APEX DRUGS & INTERMEDIATES LTD SY.NO.10, IDA GADDAPOTHARAM,
JINNARAM (M), MEDAK (D) ANDHRA PRADESH
M/S Pridhvi Enviro Tech pvt. Ltd Studies & Documentation By
Submitted by M/S APEX DRUGS & INTERMEDIATES LTD, 184/C, Lawn House
(MoE&F O.M – S.NO: 118)
SY.NO 10, GADDAPOTHARAM(V) VengalRao Nagar JINNARAM(M), Hyderabad-500038 MEDAK (D) Ph: 040-40179770 ANDHRA PRADESH Fax: 040-66730926 E-Mail: pvr@pridhvienviro.com
SUBMITTED TO
MINISTRY OF ENVIRONMENT & FORESTS, GOI PARYAVARAN BHAWAN, CGO COMPLEX,
LODHI ROAD, NEW DELHI-110003
CONTENTS
S.No. Description Page No. 1. Introduction 1 2 Introduction of the project 2 About the Group & Promoters 3 3 Project Description 4 3.1 Production Capacity 4 3.1.1 Proposed Expansion 4 3.2 Manufacturing Process 5 3.3 Raw materials 5 3.4 Water Requirement 5 3.5 Waste generation and control systems 6 3.5.1 Liquid effluents 6 3.5.2 Solid waste management 9 4 Site Analysis 10 4.1 Plant location 10 5 Planning in Brief 17 6 Resource requirement 17 6.1 Power requirement and Supply/ Source 17 6.2 Production facilities , Utilities and
effluent handling facilities 17
6.3 Land requirement 18 7 Air pollution 18 8 Bulk chemical storage 19 9 Project financial 20
LIST OF TABLES
LIST OF FIGURES
LIST OF ANNEXURES
Table No. Description Page No. 1.0 Salient Features of the Project 2 2.0 List of Existing Products and Capacity 3 3.0 Proposed Products and Capacity 4 4.0 Water Balance-Current & Proposed 5 5.0 Solid Waste and Disposal 9 6.0 List of Reserve Forests 10 7.0 Utilities and Effluent Handling Facilities
Existing and Proposed 17
8.0 Land Statement 18
9.0 Emission Source – Current & Proposed 18
10.0 Storage facilities of bulk chemicals 19
Fig No Description Page No. 1.1 Schematic treatment scheme of high
TDS effluents 7
1.2 Low TDS Effluent Treatment System 8 1.3 Base Map of the Study Area 12 1.4 Topo Map of the study area 13 1.5 Photographs of Plant & Green Belt 14-15 1.6 Site Plan 16
Annexure Description I CFO copy II List of Raw Material III Technical details of proposed products
ANNEXURE III
TECHNICAL DETAILS OF PROPOSED PRODUCTS
Apex Drugs & Intermediates Limited
Form I Page 1
APPENDIX – I (See Paragraph – 6)
FORM I
I) Basic Information
S.No. Item Details 1 Name of the Project/s APEX DRUGS & INTERMEDIATES LIMITED 2 S. No in the Schedule 5 f – Drug & Drug Intermediates 3 Proposed capacity/area/length/tonnage to
be handled/command area/lease area/number of wells to be drilled
Capacity expansion from 15.0 TPM to 28.5 TPM
4 New/Expansion/Modernization Expansion 5 Existing Capacity/Area etc. Recovery of Solvents & Piperazine 15.0 TPM 6
Category of Project i.e 'A' or 'B'
“A”( As the unit is located in 10 Km radius of Bollaram & patancheru cluster which is notified under CEPI )
7 Does it attract the general condition? If yes, please specify
No
8 Does it attract the Specific condition? If yes, please specify.
No
9 Location Plot/Survey/Khasra No. Sy.No- 10, Village IDA Gaddapotharam Tehsil Jinnaram (Mandal) District Medak (District) State Andhra Pradesh
10 Nearest railway station/airport along with distance in kms.
Gaudavalli at distance of 10 Kms from the site Shamshabad is nearly 40 Kms from the site
11 Nearest Town, City, District Headquarters along with distance in kms.
Gaddapotharam – 0.82 Kms from the site Sanga Reddy at about 50 Kms from the site
12 Village Panchayats, Zilla Parishad, Municipal Corporation, Local body (complete postal address with telephone nos. to be given)
Gaddapotharam ( Gram Panchayat) Jinnaram ( Mandal) Medak ( District) Andhra Pradesh
13 Name of the Applicant M/s. Apex Drugs & Intermediates Limited 14 Registered Address 210, Ram’s Enclave,
Erragadda, Hyderabad, Andhra Pradesh. Phone: 040-23706034 Fax: 040-23707368 Mail: vijayreddy @apexdrugs.net
Apex Drugs & Intermediates Limited
Form I Page 2
15 Address for Correspondence: Name Mr. GHANSHYAM KURMI (ManagingDirector) Designation(Owner/Partner/CEO) Owner Address 210, Ram’s Enclave,
Erragadda, Hyderabad, Andhra Pradesh.
Pin Code 500018 E-mail vijayreddy @apexdrugs.net Telephone Number 040-23706034
Fax No. 040-23707368 16 Details of alternative Sites examined, if any.
Location of these sites should be shown on a topo sheet.
- NA- This is existing unit
17 Interlinked Projects -NA- 18 Whether separate application of interlinked
project has been submitted? -No -
19 If yes, date of submission -NA - 20 If no, reason 21 Whether the proposal involves
approval/clearance under: if yes, details of the same and their status to be given. (a) The Forest (Conservation) Act, 1980? (b) The Wildlife (Protection) Act, 1972? (c) The C.R.Z Notification, 1991?
-NA-
22
Whether there is any Government Order/Policy relevant/relating to the site?
GO MS No 95 of EFES&T Department, Government of AP dated 21.9.2007 on restriction on expansion and establishment of new industries – IDA Gaddapotharam area is identified as one of the restricted area. GO MS No: 64 on lifting of ban on expansion of Drugs and Drug Intermediate units with ZLD facilities
23 Forest land involved (hectares) No 24 Whether there is any legal cases pending
against the project and /or land in which the project is propose to be set up? (a) Name of the Court (b) Case No (c) Orders/directions of the Court, if any and its relevance with the proposed project.
No
Apex Drugs & Intermediates Limited
Form I Page 3
(II) Activity
1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
S. No.
Information/Checklist confirmation Yes/No Details thereof (with approximate
quantities /rates, wherever possible) with source of information data
1.1 Permanent or temporary change in land use, land cover or topography including increase in intensity of land use (with respect to local land use plan)
NO The proposal is for expansion of the manufacturing capacity in the existing Solvent & Piperazine Recovery unit.
1.2 Clearance of existing land, vegetation and buildings?
NO No existing buildings or vegetation will be disturbed
1.3 Creation of new land uses? NO Existing land use – Industrial. 1.4 Pre-construction investigations e.g.
bore houses, soil testing? NO Existing unit.
1.5 Construction works?
YES Construction activity involves creation of additional utilities. One production block & 3 clean room are proposed and ZLD facilities
1.6 Demolition works? NO
1.7 Temporary sites used for construction works or housing of construction workers?
NO Labor is employed from nearby villages
1.8 Above ground buildings, structures or earthworks including linear structures, cut and fill or excavations
YES No major cut and fill or excavation is anticipated.
1.9 Underground works including mining or tunneling?
NO
1.10 Reclamation works? NO 1.11 Dredging? NO 1.12 Offshore structures? NO 1.13 Production and manufacturing
processes? YES This is Solvent & Piperazine Recovery unit.
Details given in pre-feasibility report 1.14 Facilities for storage of goods or
materials? YES Existing facilities for storage of chemicals
are used 1.15 Facilities for treatment or disposal of
solid waste or liquid effluents? YES Currently the unit established evaporation
facilities for process and washes. It is now proposed to establish ZLD plant. Details submitted in pre-feasibility report.
1.16 Facilities for long term housing of operational workers?
NO
Apex Drugs & Intermediates Limited
Form I Page 4
1.17 New road, rail or sea traffic during construction or operation?
NO
1.18 New road, rail, air waterborne or other transport infrastructure including new or altered routes and stations, ports, airports etc?
NO
1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements?
NO
1.20 New or diverted transmission lines or pipelines?
NO
1.21 Impoundment, damming, culverting, realignment or other changes to the hydrology of watercourses or aquifers?
NO
1.22 Stream crossings? NO 1.23 Abstraction or transfers of water
from ground or surface waters? NO Project needs about 81.4 KLD of water
which is proposed to be procured from tankers in which 51.2 KLD is freshwater requirement and 30.2 KLD is recycled water.
1.24 Changes in water bodies or the land surface affecting drainage or run-off?
NO
1.25 Transport of personnel or materials for construction, operation or decommissioning?
YES Transport of material for construction will be there for short period during construction.
1.26 Long-term dismantling or decommissioning or restoration works?
NO Existing plant
1.27 Ongoing activity during decommissioning which could have an impact on the environment?
NO Existing plant
1.28 Influx of people to an area in either temporarily or permanently?
NO All labor is taken from nearby villages or Hyderabad
1.29 Introduction of alien species? NO
1.30 Loss of native species or genetic diversity?
NO There are no losses of tree/shrub species.
1.31 Any other actions? NO
Apex Drugs & Intermediates Limited
Form I Page 5
2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):
S.No. Information/checklist confirmation Yes/No Details thereof (with approximate quantities /rates, wherever possible) with source of information data
2.1 Land especially undeveloped or agricultural land (ha)
NO Existing Unit. The total area of the plant is 3.0 acres. Out of this green belt area is 0.9 acres. Land already developed is 1.04 acres and the land required for proposed expansion is 0.09 acres
2.2 Water (expected source & competing users) unit: KLD
YES Purchased from tankers (Water Balance submitted in pre-feasibility report)
2.3 Minerals (MT) NA
2.4 Construction material – stone, aggregates, sand / soil (expected source – MT)
YES As it is proposed to add few utilities and ZLD facilities, construction material like steel, sand, cement, aggregate, bricks will be used.
2.5 Forests and timber (source – MT) NO 2.6 Energy including electricity and fuels
(source, competing users) Unit: fuel (MT), energy (MW)
YES The total power requirement after expansion would be 950 KVA and the same is drawn from APCPDL. During load shut downs backup DG sets will be used. Coal is procured from local sources. Approximate coal requirement is 20.0 TPD
2.7 Any other natural resources (use appropriate standard units)
NO
Apex Drugs & Intermediates Limited
Form I Page 6
3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.
S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data
3.1 Use of substances or materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies)
YES Hazardous chemicals shall be used for manufacturing of Drugs & Drug Intermediates. Safety measures are taken for the storage of hazardous waste.
3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases).
NO No such diseases are expected
3.3 Affect the welfare of people e.g. by changing living conditions?
YES Shall increase the employment potential for locals and affect the living conditions for betterment
3.4 Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderly etc.,
NO No sensitive receptors are present in the immediate vicinity of the site. The project shall not have any significant impact on vulnerable groups of people.
3.5 Any other causes NO
4. Production of solid wastes during construction or operation or decommissioning (MT/month) S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate
quantities/rates, wherever possible) with source of information data
4.1 Spoil, overburden or mine wastes NO 4.2 Municipal waste (domestic and or
commercial wastes) NO Wastes from canteen, other commercial
wastes like paper, empty containers etc. The canteen wastes and commercial wastes shall be in the range of 0.5 TPM
4.3 Hazardous wastes (as per Hazardous Waste Management Rules)
YES Solid waste 47.23 TPM generated sent to TSDF for secured land fill and Incinerable waste to Cement plants for Co- incineration.
4.4 Other industrial process wastes YES Details submitted in pre-feasibility report
4.5 Surplus product NO 4.6 Sewage sludge or other sludge from
effluent treatment YES Details submitted in pre-feasibility report
4.7 Construction or demolition wastes NO
4.8 Redundant machinery or equipment NO
Apex Drugs & Intermediates Limited
Form I Page 7
4.9 Contaminated soils or other materials NO
4.10 Agricultural wastes NO
4.11 Other solid wastes NO Details given in pre-feasibility report
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data
5.1 Emissions from combustion of fossil fuels from stationary or mobile sources
YES Coal is used as fuel. Particulate matter, CO2, SO2 and NOX are emissions. Bag Filters were installed for existing boilers and for proposed 4 TPH Boiler.
5.2 Emissions from production processes YES Process emissions are primarily CO2, H2 which are safely let into atmosphere and HCl Emissions are scrubbed.
5.3 Emissions from materials handling including storage or transport
YES Material transfer takes place in closed pipeline systems.
5.4 Emissions from construction activities including plant and equipment
Yes Water sprinklers will be used to suppress dust
5.5 Dust or odors from handling of materials including construction materials, sewage and waste
Yes Dust will be suppressed with water sprinkling during construction
5.6 Emissions from incineration of waste NO 5.7 Emissions from burning of waste in
open air (e.g. slash materials, construction debris)
NO
5.8 Emissions from any other sources NO
Apex Drugs & Intermediates Limited
Form I Page 8
6. Generation of Noise and Vibration, and Emissions of Light and Heat: S.No. Information/Checklist
confirmation Yes/No Details thereof (with approximate
quantities/rates, wherever possible) with source of information data with source of information data
6.1 From operation of equipment e.g. engines, ventilation plant, crushers
YES Material transport and construction equipment shall be source of noise, while transfer pumps, vacuum systems, DG sets are the sources of noise during operation.
6.2 From industrial or similar processes
YES From DG sets, and controlled by providing Acoustic Enclosures.
6.3 From construction or demolition NO No significant impact is anticipated.
6.4 From blasting or piling NO
6.5 From construction or operational traffic
NO The increased vehicle movement shall not have any significant impact.
6.6 From lighting or cooling systems NO
6.7 From any other sources NO
7.Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal waters or the sea:
S.No. Information/Checklist confirmation
Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data
7.1 From handling, storage, use or spillage of hazardous materials
Yes All the hazardous materials is stored on elevated plat form and stored in a closed storage tanks/containers (Liner/MS/GI/HDPE) in a covered shed with spill collection and control systems and no contamination of soil is expected.
7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of discharge)
NO All the wastes from domestic operations are sent to effluent treatment plant and the treated water is being used for utilities and gardening
7.3 By deposition of pollutants emitted to air into the land or into water
NO Process emissions are primarily CO2, H2 which are safely let into atmosphere and HCl Emissions are scrubbed.
7.4 From any other sources NO 7.5 Is there a risk of long term build
up of pollutants in environment from these sources?
NO
Apex Drugs & Intermediates Limited
Form I Page 9
8.Risk of accidents during construction or operation of the Project, which could affect human health or the environment
S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data
8.1 From explosions, spillages, fires etc from storage, handling, use or production of hazardous substances
YES All Inbuilt Safety precautions will be adopted and there will not be any damage to environment or human health.
8.2 From any other causes NA
8.3 Could the project be affected by natural disasters causing environmental damage (e.g? Floods, earthquakes, landslides, cloudburst etc)?
NO
9.Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality
S. No.
Information/Checklist confirmation Yes/No Details thereof (with approximate quantities/rates, wherever possible) with source of information data
9.1 Lead to development of supporting. facilities, ancillary development or
development stimulated by the project which could have impact on the environment e.g.:
• Supporting infrastructure (roads, power supply, waste or waste water treatment, etc.) • housing development • extractive industries • supply industries • other
YES The project shall enhance the socio economic status of the area by increasing the demand for housing, improving the employment. There are no major support industries required for this plant.
9.2 Lead to after-use of the site, which could haven impact on the environment
NO
9.3 Set a precedent for later developments NO
9.4 Have cumulative effects due to proximity to other existing or planned projects with similar effects
Yes There is possibility of cumulative impacts as other units in industrial area can go for expansion
Apex Drugs & Intermediates Limited
Form I Page 10
(III) Environmental Sensitivity S.No. Areas Name/
Identity Aerial distance (within 15 km.) Proposed project location boundary
1 Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other related value
NA
2 Areas which are important or sensitive for ecological reasons - Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests
NO
3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration
NO
4 Inland, coastal, marine or underground waters NO 5 State, National boundaries NO 6 Routes or facilities used by the public for access
to recreation or other tourist, pilgrim areas NO
7 Defense installations YES 6.5 Kms – Hakimpet Air Force Station
8 Densely populated or built-up area No
9 Areas occupied by sensitive man-made land uses (hospitals, schools, places of worship, community facilities)
NA
10 Areas containing important, high quality or scarce resources (ground water resources, surface resources, forestry, agriculture, fisheries, tourism, minerals)
NO
11 Areas already subjected to pollution or environmental damage. (those where existing legal environmental standards are exceeded)
NO
12 Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)
NO
Apex Drugs & Intermediates Limited
Form I Page 11
(IV) Proposed Terms of Reference for EIA studies Scope of Work of EIA
“...The EIA shall cover the following: Description of the proposed project: The first task:” Description of the proposed project” forms a vital component of the Environmental Impact Assessment (EIA) as it provides the basis for evaluating the likely causes of Environmental Impacts.
Existing Environment and Baseline Conditions: The baseline assessment will be carried out to identify potentially sensitive and critical areas that may be affected by the project in an area of 10 km surrounding the project location. The critical and sensitive targets shall be plotted on land use map of project impact area. The existing environment and baseline conditions should be established from:- Analysis of existing information published and secondary data. -Consultation with relevant statutory authorities, and Field visits for supplementation of missing gaps.
The key subject areas which the EIA shall address include Ecology and Nature conservation, Air quality, surface and water quality in project impact area, soil quality, cultural heritage, landscape, land use, noise quality, etc. Natural habitats like national parks, wildlife reserves, sanctuaries, sacred grove, protected areas, forests, wetlands, major rivers and waterways if any, shall also be identified and marked.
Assessment of Environmental Impacts: Based upon the results from the review of existing information, field visits, site data collection and consultation, for each component of environment (physical, biological and socio economic) the positive, negative, direct and indirect, temporary and permanent impacts will be evaluated along with an indication of the degree of impact, i.e., whether the impact is significant, moderate, minor or negligible. The degree of impact shall also be quantified by using state of the art air quality impact prediction models based on ISCST3 algorithms.
Environment Management Plan And Mitigation Plan: For each significant negative impact identified, specialist shall work closely with the engineering team/technical consultants to suggest practicable measures to avoid or mitigate the impact. The mitigation of environmental impacts will be by three mechanisms. =>Introduction of mitigation features through the engineering practices. =>Implementation of environmental controls during construction and operation. =>Legislative control involving compliance with Indian environmental laws. The Environmental management plan shall include an estimate of capital and recurring costs of mitigation measures and will identify the institutional framework for implementation.
Monitoring Plan: Having identified the significant environmental impact that is likely to arise as a result of the project, the project team shall specify what monitoring is required during the various phases of the project cycle. The monitoring plan will identify parameters and frequency of monitoring and responsible organization.
Apex Drugs & Intermediates Limited
Form I Page 12
BASIC INFORMATION FOR TOR PROPOSAL OF M/S APEX DRUGS & INTERMEDIATES LIMITED, Sy. NO.10, IDA
GADDAPOTHARARAM, JINNARAM (M), MEDAK DISTRICT, ANDHRA PRADESH
Agenda Item No. Name of Project:
M/S Apex Drugs & Intermediates Limited Capacity Expansion of (5 f) organic chemicals and Intermediates manufacturing unit
If expansion, state status of implementation of project for which EC has been accorded : NO previous EC’s
Name of Project Proponent:
Ghanshyam Kurmi (Managing Director) M/S APEX DRUGS & INTERMEDIATES LIMITED, IDA GADDAPOTHARARAM JINNARAM (M), MEDAK DISTRICT, ANDHRA PRADESH.
Name of Consultant & QCI No.:
M/s Pridhvi Envirotech Pvt.Ltd S.No 118 in list of accredited consultants ( rev 13 October, 2013)
Sl. No. Salient Features 1.
Location of project Village : Taluk : District : State : Co-ordinates :
Sy. NO 10, Gaddapotharam (V) Jinnaram Mandal Medak District Andhra Pradesh N 170
E 7927’.01” Latitude &
010’.01” Longitude 2. Capacity & Unit Configurations: Capacity Expansion from 15 TPM to 28.5
TPM Number of Days operation in a year Full year Products to be manufactured (TPD/MTPA)
Details given in prefeasibility report
3. Land requirement: Total land area is 3.0 acres
4. Status of Land acquisition: Land is in possession of the company 5.
Break-Up of Land-Use of project site:
Forests land (Type and density) : None Detailed land use shall be provided with EIA Double Crop agricultural land : Single crop agricultural land : Waste land :
Grazing land : Others (specify) : Land is in possession of the company which is converted to industrial use
6 Whether project located in the notified Industrial area
Yes in IDA Gaddapotharam
7. Fuel to be used: Coal is used for boiler 8.
Quantity of Fuel Required per Annum: Coal 20.0 TPD
9 Source of Water: Purchased from private parties through tankers
10 Water Quantity:
Water requirement after Expansion-81.4 KLD Fresh water requirement – 51.2 KLD
11 Quantity of industrial effluent generation and domestic wastewater generation.
35.8 KLD – Industrial waste water 3.0 KLD - Domestic
12 Effluent treatment process proposed Industrial Effluents are proposed to be evaporated in MEE followed by ATFD Domestic effluents along with MEE condensate proposed to be treated in biological treatment system followed by RO. RO Permeat proposed to be re-used and RO rejects goes back to MEE
13
Disposal of treated effluent Zero Liquid discharge
14 Membership of CETP society (if existing)
--
15 Details of process emissions HCl, H2 and CO2 emissions 16 Proposed air pollution control device
alongwith stack height Process emissions are scrubbed Fugitive Emissions – vent condensers and chillers Stack heights are provided as per the guidelines of CPCB for effective dispersion of emissions
17 Details hazardous waste generation Details given in prefeasibility report 18
Management of hazardous waste (Treatment & Disposal)
TSDF and authorized recyclers
19 Membership of TSDF (if existing) Yes 20 Quantity of Fly Ash to be Generated: 7.6 Tons/day. Will be sold to brick
manufacturers 21. Greenbelt area proposed 3700.0 Sqm 22.
CRZ Clearance Status, if any
Not applicable as this does not comes under CRZ clearance
23. Names & distance of National parks, Wildlife sanctuaries, Biosphere reserves, Heritage sites Rivers, Tanks, Reserve Forests etc. Located within 10 Km from the plant boundary:
There are no National parks, wildlife sanctuaries, bio sphere reserves etc. within 10 KM from the site.
24.
Any litigation/Court case pertaining to the project:
None
25 Cost of the Project: Rs (in Crores) Current Rs. 7.75 Crores Proposed-22.005 Crores
Pre-Feasibility Report Apex Drugs & Intermediates Ltd- Unit II
1
1. Introduction
M/s. Apex Drugs & Intermediates Limited is located at Survey No: 10,
IDA, Gaddapotharam (V), Jinnaram (M), Medak (D) in Andhra Pradesh.
The unit was established in 2003. Subsequently obtained CFO of the
Board vide Consent Order No: APPCB/PTN/BLM/361/CFO/HO/2011 for
Recovery of Solvents & Piperzine with a capacity of 15.0 TPM.
As Recovery units were not covered under EIA Notification of 1994 prior
EC requirements were not there. As now the industry proposed to
manufacture drugs & drug intermediates with a capacity of 28.5 TPM this
application was made for getting Environmental Clearance. As 2006
notification covers both Drugs and Drug intermediates, It is now applied
for EC for expanding the capacity.
A copy of CFO of the Board are enclosed at Annexure- I
Pre-Feasibility Report Apex Drugs & Intermediates Ltd- Unit II
2
2. Introduction of the Project
The salient features of the project are described in table below
TABLE 1.0
Salient Features of the Project
Location Survey No: 10, IDA, Gaddapotharam (V), Jinnaram (M), Medak (D), Andhra Pradesh.
Longitude and latitude 17°27'.01"N Latitude and 79°10'01"ELongitude.
Year of establishment 2003 Product category 5(f), Drugs &Drug Intermediates Project category as per EIA notification
Category A (As the unit is located in 10Km radius of Bollaram and Patancheru clusted which is notified under CEPI)
Proposed Activity Capacity expansion from 15 TPM to 28.5 TPM
Total investment on the plant Current - Rs. 7.75Crores& Proposed – Rs.22.005 Crores
Total Investment on Environmental Infrastructure
Rs. 3.0 Crores (Current) Rs. 4.0Crore ( Proposed)– Total 7.0 Crores
Total area of the plant 3.0Acres Total area of green belt 0.9 Acres Water requirement Total Water requirement-81.4 KLD
Fresh water requirement-51.2 KLD Recycled water-30.2 KLD
Source of water Purchased from outside through tankers
Nearest habitation and distance from the site
Gaddapotharam(V) at a distance of 0.82 Km from the site
Nearest surface water bodies Rainfed tank at Gaddapotharam is located 0.7 Kms from the site
Nearest reserve forest Kistaipalli reserve forest at a distance of 0.32Kms in West direction
Environmentally sensitive areas within 10 km radius
None
Any national parks, wild life sanctuaries within 10 km radius
None
Nearest air port and distance Rajiv Gandhi International Airport,Shamshabad is Nearly 40 Kms from the plant site
Nearest railway station and distance
Gaudavalli at distance of 10 Kms from the site
Pre-Feasibility Report Apex Drugs & Intermediates Ltd- Unit II
3
i) About the Group &Promoters
Apex Drugs & Intermediates Limited was established by M/S SAS
Technologies in the year 2003. M/S Apex Drugs & Intermediates Limited
represented by its Managing Director Mr. GHANSHYAM KURMI took over
the facility in the year 2006.
Apex Drugs & Intermediates Limited is well known manufacturing
company in therapeutic segments such as Anti-histamine, Anti-
Thrombotic, Anti- Inflammatory and Anti- Ulcerative.
Apex Drugs & Intermediates Limited is manufacturing and marketing APIs
& Intermediates from its unit-I located in Sy. No. 14, which is established
in 1988. Over 20 years manufactures and supplies APIs to most of Top 20
Pharma companies in INDIA and also to some reputed MNCs abroad.
The Apex is adopting cleaner environment technologies and complying to
the directions issued by APPCB from time to time. The industry made and
continuously making all efforts to treat liquid solid & Air to achieve
standards prescribed. Upgrading the facilities time to time as per the
technologies available.
Pre-Feasibility Report Apex Drugs & Intermediates Ltd- Unit II
4
3. Project Description 3.1 Production Capacity
TABLE 2.0
LIST OF EXISTING PRODUCTS
S.No Name of the Product Quantities in TPM
1. Spent solvent distillation 10 2 Recovery of Piperazine 5.0 Total 15.0
3.1.1 Proposed expansion:
It is now proposed to expand the existing production capacity by adding 5
New products. Below Table provides list of products and proposed
capacities.
TABLE 3.0
PROPOSED PRODUCTS & CAPACITY
S.No Product Name Production Capacity
TPM
Product Description
Drug/Intermediate/Multipurpos
e chemicals
1 Clopidogrel Hydrogen Sulfate 10.00 Bulk Drugs
2 Nimesulide 10.00 Bulk Drugs
3 Cetirizine Dihydrochloride 3.00 Bulk Drugs
4 LevocetirizineDihydrochloride 0.50 Bulk Drugs
5 Pantoprazole Sodium Sesquihydrate 5.00 Bulk Drugs
Total 28.50
Bi Products
1 Ammonium Tartrate 5.5 TPM
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2 PiperizineDi-hydrochloride 1.15 TPM
3.2 Manufacturing Process
The detailed manufacturing process and process flow sheets are enclosed
at Annexure III
3.3 Raw Materials
List of raw material product wise is given at Annexure II
3.4 Water Requirement The water requirement is met from private suppliers through tankers. The
requirement for water in this unit is for process and domestic purposes.
The water balance for daily consumption is presented below.
TABLE 4.0
Water Balance– Current & Proposed
S. No Stream
Water requirement in KLD
Waste Water discharge in KLD
Method of Treatment and
Disposal Curre
nt After Expansion
Current
After Expansi
on 1 Process 0.5 19.6 0.5
22.1 Stripper, MEE and
ATFD (condensate to RO)
2 Washings 3.0 3.0 Stripper, MEE and ATFD (condensate to RO)
3 Boiler Feed 12.0 36.0 0.3 7.2 ETP Followed by RO (RO Reject to MEE)
4 Cooling tower
8.0 12.0 0.2 1.2 ETP Followed by RO (RO Reject to MEE)
5 DM/Softener back washes
-- 2.3 -- 2.3 ETP Followed by RO (RO Reject to MEE)
6 Domestic 1.5 3.5 1.0 3.0 ETP Followed by RO 7 Gardening 2.0 5.0 ---- ----
Total 24.0 81.4 2.0 38.8
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3.5 Wastes generation and control systems
3.5.1 Liquid Effluents As detailed in table 4.0 waste water generation after expansion would be
38.8 KLD. It is proposed to segregate effluents into high COD and High
TDS stream and Low COD and Low TDS streams.
High TDS and High COD stream would be treated in stripper followed by
MEE and ATFD. The resultant sludge would be disposed to TSDF,
Hyderabad. The Low TDS stream would be treated along with MEE/ATFD
condensates in biological ETP followed by RO. The RO rejects would be fed
back to MEE. The Permeate from RO would be used for cooling tower
make up. Thus the treatment system proposed is based on “Zero Liquid
Discharge” (ZLD) Concept
The schematic diagrams of ETP proposed are given in Figure 1.1 and
Figure 1.2 below
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Fig 1.1
Schematic treatment scheme of high TDS effluents
Effluent from
Process and Aq. Distillate to cement plant/ Authorized recyclers
washings , Scrubber R&D
RO Reject To TSDF Condensate to Biological Treatment Condensate to Biological Treatment
Sludge to TSDF
Stripper Setting
Tank Neutralization
Tank Equalization
Tank
MEE
ATFD
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Fig 1.2 Low TDS Effluent Treatment System
Domestic effluent
Effluents from utilities & MEE condensate
Sludge to TSDF
Permeate for re-use
Rejects to MEE
Screen Chamber
Sludge Holding Tank
Aeration Tank2
Equalization Tank
Neutralization Tank
Clarifier2
Holding
Tank
Filter Press Sludge Cake
Aeration Tank1
Clarifier1
Sand filter
Carbon Filter
Ultra filtration RO
Screen Chamber
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3.5.2 Solid wastes management
Hazardous and non - hazardous wastes generated from the proposed
expansion project are detailed below. Mode of disposal are also identified
and listed. Adequate storage of hazardous waste is ensured at the site
TABLE 5.0 Solid Wastes and Disposal
S.No Description
Quantity
Remarks Current After Expansion
TPM
1
Forced Evaporation salts & ETP sludge/MEE Salts
200 Kgs/ Day 35.0 TPM Sent to TSDF
2 Process in-organic waste
600 Kgs/ Month
0.23 TPM
Sent to TSDF, Dundigal
3 Spent caustic lye 18 KLM --
4 Spent carbon 500 Kgs/Month 0.89 TPM
5 Distillation bottom residue/ Organic resiude
4 TPM 11.11 TPM
6 Ash from boiler - 7.6 TPD Sold to brick manufacturers
7 Waste oil 3.0 Lts/ Month
10Lts/ Month
Authorized reprocessors/
recyclers
8
Container and container liners of hazardous waste & chemicals
20 Nos/ Month
100 Nos/ Month
After detoxification should be disposed to outside agencies
9 Spent solvents 13 TPM ---
10
*Piperazine MLs from unit 1 for their sister concern unit
15 TPM ----
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TSDF facility is 1.14 KM from the site in Medak District which is created
for catering the industries in this area. Transport of Hazardous wastes to
TSDF is done by the facility. In case other hazardous wastes, authorized
recyclers will transport the wastes.
4. Site Analysis 4.1 Plant Location M/s Apex Drugs & Intermediates Limited (Unit-II) is located at Sy. No
10, IDA Gaddapotharam(V), Jinnaram(M), Medak District, Andhra
Pradesh. The site is situated at 17035’30.3”N Latitude and 780
The site is surrounded by other industries of IDA Gaddapotaram.
Following are the surroundings of the site
22’30.0”E
Longitude. The total land area of the plant is 3.0 acres. The nearest
habitation from the site is Gaddapotharam (V) at a distance of 0.82 km.
The nearest railway station is located at Gaudavalli at a distance of 10
Kms from the site. There are no ecologically sensitive areas like national
parks, sanctuaries within 10 km radius of the site.
North –12m wide road and Mylan Laboratories
South – open land
East – Virchow Chemicals
West - open land
Following 19 reserve Forests are there within 10 KM radius of the site
Table 6.0
Reserve Forests in the study area
S.No Reserve Forest Direction from the site
Distance from the site
1 Dundigal E 0.8 2 Kistaipalli W 0.32 3 Kazipalli SW 0.7 4 Wailal W 1.6 5 Pottaguda W 6.2
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6 Kodakanchi W 8.4 7 Pochampalli E 6.5 8 Gudavalli E 8.3 9 Borampet E 5.14 10 Suraram E 5.9 11 Gajularamaram E 6.15 12 Dulapalle E 8.1 13 Palem NW 7.5 14 Jinnawaram NW 5.9 15 Mangampet NW 7.5 16 Royyapalli NW 9.4 17 Bontapalli NW 6.3 18 Mamdapur NW 9.6 19 Dabilpur NE 9.0
Topo graphic features of the site and 10 KM study area and base map are
given at Fig 1.3 & 1.4.
Plant & Green Belt Photographs are given at Fig. 1.5
Site Plan is given at Fig 1.6
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Fig 1.3 Base Map of the Study Area
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Fig 1.4 Topo Map of the Study Area
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Fig 1.5. Photographs of Plant & Green Belt
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Fig 1.6 Site Plan
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5.0 Planning in Brief
The project is envisaged to be completed by August 2014, and the
production shall be initiated thereon. Consultants are identified for
preparing the detailed project report.
6. Resource requirements
6.1 Power Requirement and Supply/Source
The total power requirement is 950 KVA and meet through APCPDL With
100%power backup by DG sets.
6.2 Production facilities, Utilities and effluent handling facilities
Apart from the existing facilities it is proposed to add additional production facilities, utilities and effluents treatment infrastructure with an additional investment of Rs. 22.005 Cores. The details are outlined in the below table
TABLE 7.0 Production facilities/Utilities/ETP – Existing & Proposed
S.NO Details Capacity/
No Current Additions After
expansion
Production facilities
1 Production Blocks- - 2 1 3 2 Clean rooms - - 3 3 Utilities 3 Boiler ( coal Fired) TPH 2X2 4 8 4 DG sets KVA 480
1 x 160, 1 x 320
1 X500 980
5 Cooling tower TR 2X 200 2X200 800 6 Softner/DM plant M3/day 2X25 2X25 100 Effluent handling & treatment facilities 7 collection tanks-
Storage KL 40 - 40
8 Neutralisation tanks KL 40 -- 40 9 Stripper ,MEE,ATFD KLD 50 - 50 10 RO & Biological
treatment KLD - 50 50
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6.3 Land Requirement
The unit currently has 3 acres of land and out of which 0.9 acres of green
belt is developed. The land requirement for proposed expansion activities
will be 0.09 acres which can be met from existing open area. Below table
provides the land statement. Detailed site lay out plan outlining current
and proposed expansion activities is given at Figure 1.5
Table 8.0 Land Statement
S.NO Purpose Units Extent 1 Built up area Sq.M 4225 2 Green belt Sq.M 3700 3 Open area Sq.M 4228 Total Sq.M 12153 4 Area required for Proposed expansion Sq M 350
7.0 Air Pollution
The Sources of air emissions from the plant are 2 TPH & 4 TPH coal fired
boiler, DG sets and from process. Following table provides information
about the air pollution sources and proposed control measures
The process emissions from the second phase contain HCl, H2 and CO2
Table 9.0
.
HCl fumes are scrubbed with water or with caustic soda scrubbed waste
send to MEE. The other gases expected in the process are Carbon dioxide
& H2 which are let out into atmosphere. Below Table gives current &
proposed emission sources from the plant.
Emission Source – Current & Proposed
S.NO Source Capacity
Fuel Anticipated emissions
Control system
Current
1 Boiler 2X2 TPH Coal SPM,SO2 & NOx
Bag filter
2 DG sets 1 x 160 KVA, 1 x 320 KVA
Deisel SPM, SO2, NOX
Acoustic enclosure
3 Process emissions -- -- -- --
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Proposed additions 5 Boiler ( coal Fired) 4 TPH Coal SPM,SO2
&NOx Bag filter
6 DG sets 1 x 160 KVA, 1 x 320 KVA,
1 X500
Diesel SPM, SO2 &NOx
Acoustic Enclosure
7 Process emissions -- -- HCl,H2and CO2
Scrubber
8.0 Bulk Chemical Storages:
Following bulk chemical storage facilities are proposed for expansion activity
Table No 10.0
Storage facilities of bulk chemicals
Sr No
Capacity (KL) Name of the solvent MOC
1 30 Methanol MS 2 30 Toluene MS 3 30 Acetone MS 4 20 IPA MS 5 20 Di chloromethane MS
Total maximum storage capacity: 130 KL
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9. Project Financial
The estimated cost of the expansion project is approximately 22.005
Crores. Out of this Rs. 4 Crores will be for environmental infrastructure
and rest for other process equipment and safety equipment
Project cost Rs. In lakhs Plant& machinery 1700 Civil buildings 213 Steel Structures 20
Total 1933
Pipe lines & insulation 10% on plant & machinery 17
Electricals & instrumentation 10% on plant & machinery 17
Erection & commissioning & painting
5% on plant & machinery and structures 8.5
Environment & Safety infrastructure 50 Furniture, fixtures, computers, lighting etc 25
Total 117.5 Contingencies & pre-operative expenses 150
Total Project cost 2200.5
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Annexure I
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Annexure II
List of Raw Materials
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List of Raw Materials
Clopidogrel Hydrogen Sulfate
S.No. Raw Material Quantity (Kgs/Day)
1 2-(Thiophen-2-yl)ethyl Acetate 182.4 2 Acetone 653.6 3 Ammonia (10%)solution 380 4 Ammonia (23%)solution 68.4 5 Carbon 6.08 6 Couple Amine Hydrochloride 304.0 7 Formaldehyde (45%) 91.2 8 Hydrochloride acid (35%) 6.08 9 Hydrogen Chloride 7.6
10 Hyflow 3.8 11 Isopropyl Alcohol Hydrochloride (20%) 190.0 12 Methanol 767.6 13 o-Chloro Phenyl Glycine 199.12 14 Sodium Hydroxide 48.64 15 Sulfuric acid 86.64 16 Tartaric acid 164.16 17 Tartrate Salt 2.28 18 TEBAC 1.52 19 Toluene 1335.92
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List of Raw Materials
LevocetirizineDihydrochloride
S.No. Raw Material Quantity (Kgs/Day)
1 2-Chloroetahnol 4.608 2 Ammonium Formate 4.608 3 Dimethylformamide 51.2 4 Hydrochloride acid (30% in Acetic acid) 15.36 5 Hydrochloric acid (35%) 28.928 6 Hydrogen Chloride 3.84 7 Methylene Dichloride 128.0 8 N,N-(bis) Chloroethyl-4-methyl benzene
sulfonamide 16.64
9 p-ChloroBenzophenone 15.36 10 Phenol 3.84 11 Potassium Hydroxide 2.816 12 Sodium Hydroxide 26.112 13 Sodium Monochloro Acetate 7.68 14 Tartaric Acid 8.96 15 Toluene 550.4 16 Triethylamine 21.248
List of Raw Materials
Pantoprazole Sodium Sesquihydrate
S.No. Raw Material Quantity (Kgs/Day)
1 Acetonitrile 433.29 2 Carbon 16.66 3 Ethyl Acetate 183.31 4 Hyflow 3.33 5 Methylene Dichloride 1583.17 6 Pantoprazole Sulfide 183.15 7 Sodium Hydroxide 23.33 8 Sodium Hypochlorite (15%) 249.97
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List of Raw Materials
Nimesulide
S.No. Raw Material Quantity (Kgs/Day)
1 2-Phenoxy aniline 333.45 2 O-nitro chloro benzene 292.5 3 Phenol 175.5 4 Potassium hydroxide 104.13 5 Iron power 6 Ammonium chloride 7 Carbon 5.85 8 Hydrochloric acid (35%) 23.4 9 Hyflow 1.17
10 Methanesulfonyl Chloride 210.6 11 Nitric acid 128.7 12 Sodium Hydroxide 81.9 13 Toluene 2983.5
List of Raw Materials
Cetirizine Dihydrochloride
S.No. Raw Material Quantity (Kgs/Day)
1 2-Chloroethanol 37.05 2 Dimethylformamide 148.2 3 Hydrochloride acid (35%) 88.92 4 Hydrochloride Chloride 37.05 5 Methanol 370.5 6 p-ChloroBenzophenone 85.21 7 Piperazine 54.093 8 Potassium Hydroxide 55.57 9 Sodium Borohydride 8.892
10 Sodium Monochloro Acetate 54.09 11 Toluene 1259.7 12 Triethylamine 59.58
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Annexure III
Technical Details of Proposed Products
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Product : Nimesulide
Description: Stage-I o-chloro nitro benzene react with phenol in presence of potassium hydroxide ,toluene to form stage-I Stage-II stage-I reduction with iron powder in presence of ammonium chloride,toluene,water,HCl to form a stage-II Stage-III Stage-II react with methanesulfony chloride in presence of sodium hydroxide and HCl in toluene solvent and gets purified with carbon and hyflow to form stage-III compound Stage-IV Stage-III reaction with niric acid in toluene solvent to get nimesulidepharma
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Product: Nimesulide Flow chart Sol .Recovery o-chloro nitro benzene Evoporation loss phenol Efflent Toluene organic Residue potassium hydroxide water
Iron power Sol .Recovery Ammonium chloride Evoporation loss Water Efflent Con. Hydrochloric acid organic Residue Toluene
Methanesulfonyl chloride Sol .Recovery Sodium hydroxide Evoporation loss Con. Hydrochloric acid Efflent toluene organic Residue carbon spent carbon hyflow water
Sol .Recovery Nitric acid Evoporation loss Toluene Efflent Water organic Residue
STAGE-I
STAGE-II
STAGE-III
STAGE-IV
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NIMESULIDE Nimesulide reaction scheme
OH
+
N+ O
-O
Cl
+ OHK
O
N+ O
-O
+ OH2 + ClK
phenol 1-chloro-2-nitrobenzene
Molecular Formula = C12H9NO3
Formula Weight = 215.20476
O
N+ O
-O
+ +
Formula Weight = 215.20476
Molecular Formula = C12H9NO3
6H2ONH4Cl
O
NH2
1-nitro-2-phenoxybenzene
1-nitro-2-phenoxybenzene
2Fe+2 + 2Fe(OH)3+ 2H2O
2-phenoxyanilineMolecular Formula = C12H11NO
Formula Weight = 185.22184
Stage-I
Stage-II
Molecular Formula = C6H6OFormula Weight = 94.11124
Molecular Formula = C6H4ClNO2Formula Weight = 157.55446
STAGE-III
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STAGE-IV
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