Annexures 3 GCPLenvironmentclearance.nic.in/writereaddata/Online/TOR/05...Calculated quantities of...

Annexures GCPL 1

List of Annexures Annexure – I Plant Layout

Annexure – II Manufacturing Process

Annexure – III Details of Storage of Solvents

Annexure – IV Water Balance & Details of Treatment and disposal of Effluent

Annexure – V Details of Treatment and Disposal of Solid Waste

Annexure – VI List of Raw materials & Quantity of Consumption

Annexure – VII Point Source Emissions – Stack Emission Characteristics

Annexure – VIII Details of Fugitive Emissions

Annexure – IX Risk Identification

Annexure – X Topo Map & Administrative Set-up Map

Annexures GCPL 2

ANNEXURE – I PLANT LAYOUT

Annexures GCPL 3

Annexures GCPL 4

Annexures GCPL 5

ANNEXURE – II MANUFACTURING PROCESS

Annexures GCPL 6

Manufacturing Process

Exis t in g

Calcium Gluconate

Gluconic Acid procured from market is neutralized with Calcium carbonate, filtered,

crystallised, centrifuged, dried, milled and packed.

Alternate process for the manufacture of Calcium Gluconate

Gluconic acid is neutralised with Calcium carbonate, filtered, crystallised, centrifuged,

dried, milled and packed.

Alternate process

NEUTRALISATION FILTERATION

CRYSTALLISATION

PACKING MILLING DRYING CENTRIFUGING

NEUTRALISATION FILTRATION CRYSTALLISATION


GLUCONO DELTA LACTONE + CaCO3 + WATER

(NEUTRALISATION) FILTRATION CRYSTALLISATION


Annexures GCPL 7

Sodium Gluconate

Gluconic acid brought from the market is neutralised with Sodium bi-carbonate, filtered,

concentrated, crystallised, centrifuged, dried, milled and packed.

Alternate process for the manufacture of Sodium Gluconate

Gluconic acid is neutralised with Sodium carbonate / Sodium Bicarbonate, filtered,


Alternate process



CONCENTRATION

NEUTRALISATION FILTRATION

CRYSTALLISATION


CONCENTRATION

GLUCONIC ACID +

SODIUM CARBONATE /

BICARONATE

(NEUTRALISATION)

FILTRATION SIEVING

PACKING

DRYING

Annexures GCPL 8

Potassium Gluconate

Gluconic acid brought from the market is neutralized with Potassium carbonate, filtered,


Alternate process for the manufacture of Potassium Gluconate

Gluconic acid is neutralised with Potassium carbonate / Potassium Bicarbonate, filtered,


Alternate process



CONCENTRATION


CRYSTALLISATION


CONCENTRATION

GLUCONIC ACID +

POTASSIUM CARBONATE

/ BICARONATE

(NEUTRALISATION)

FILTRATION SIEVING

PACKING

DRYING

Annexures GCPL 9

Magnesium Gluconate

Gluconic acid brought from the market is neutralised with Magnesium carbonate, filtered,


Alternate process for the manufacture of Magnesium Gluconate

Gluconic acid is neutralised with Magnesium carbonate, filtered, concentrated, crystallised,

centrifuged, dried, milled and packed.

Alternate process



CONCENTRATION


CRYSTALLISATION


CONCENTRATION

GLUCONIC ACID +

MAGNESIUM CARBONATE

(NEUTRALISATION) FILTRATION SIEVING

PACKING

DRYING

Annexures GCPL 10

Zinc Gluconate

Gluconic acid brought from the market is neutralised with Zinc carbonate/Zinc Oxide,

filtered, concentrated, crystallised, centrifuged, dried, milled and packed.

Alternate process for the manufacture of Zinc Gluconate

Gluconic acid is neutralised with Zinc carbonate/Zinc Oxide, filtered, concentrated,

crystallised, centrifuged, dried, milled and packed.

Alternate process



CONCENTRATION


CRYSTALLISATION


CONCENTRATION

GLUCONIC ACID + ZINC

CARBONATE / ZINC OXIDE


PACKING

DRYING

Annexures GCPL 11

Manganese Gluconate

Gluconic acid brought from the market is neutralised with Manganese carbonate/

Manganese Oxide, filtered, concentrated, crystallised, centrifuged, dried, milled and packed.

Alternate process for the manufacture of Manganese Gluconate

Gluconic acid is neutralised with Manganese carbonate/ Manganese Oxide, filtered,


Alternate process



CONCENTRATION


CRYSTALLISATION


CONCENTRATION

GLUCONIC ACID +

MANGANESE CARBONATE /

MANGANESE OXIDE

(NEUTRALISATION)

FILTRATION SIEVING

PACKING

DRYING

Annexures GCPL 12

Calcium Lactate

Lactic Acid is neutralised with Calcium carbonate, filtered, crystallised, centrifuged, dried,

milled and packed.

Calcium Glubionate

In this process, calculated quantities of both Calcium Gluconate and Calcium Lactobionate

are charged in the blender and mixed, sieved and packed.

Alternate Process for the manufacture of Calcium Glubionate

Calculated quantities of Calcium Gluconate and Calcium Lactobionate are mixed in DM

water, filtered, dried, sieved and packed.



BLENDING SIEVING PACKING

MIXING SIEVING PACKING FILTERING DRYING

Annexures GCPL 13

Calcium Lacto Gluconate

In this process, calculated quantities of Calcium Lactate and Calcium Gluconate are charged

in the blender and mixed, sieved and packed.

2. Alternate Process for the m anu facture of Ca lciu m La ct o Glucon a t e

Calculated quantities of Calcium Lactate and Calcium Gluconate are mixed in DM water,

filtered, dried, sieved and packed.


Calculated quantities of Gluconic Acid, Lactic Acid are reacted with calcium carbonate,

filtered, dried, sieved and packed.


MIXING SIEVING PACKING FILTERING DRYING


GLUCONIC ACID + LACTIC

ACID + CaCO3


PACKING

DRYING

GLUCONO DELTA LACTONE

+ LACTIC ACID + CaCO3


PACKING

DRYING

Annexures GCPL 14

Calcium Lactobionate

Calculated quantities of Lactose, Sodium bromide, Calcium Carbonate are mixed in water,

electrolysed, filtered, vaccum concentrated, crystallised with alcohol, centrifuged, milled,

dried and packed in bags/ Fibre drums.

ELECTROLYSIS FILTRATION

CRYSTALLISATION


VACCUM

CONCENTRATION

LACTOSE,

SODIUM BROMIDE,

CALCIUM CARBONATE,

DM WATER

Annexures GCPL 15

Calcium Borogluconate :

1. Calculated quantities of calcium gluconate and Boric acid are charged in the blender

and mixed sieved & packed.

2. Alternate Process

Calculated quantities of calcium gluconate & Boric acid dissolved in DM Water, filtered,

spray dried, sieved & packed.

Ferrous Gluconate :


CALCIUM

GLUCONATE +

BORIC ACID +

DISSOLVED IN DM

WATER

FILTERED DRIED

PACKED SIEVED

CALCIUM

GLUCONATE +

FERROUS

SULPHATE + DM

WATER

FILTERATIO

N

CONCENTRATIO

N

PACKING MILLING

DRYING

Annexures GCPL 16

Man u factu rin g P rocess

P roposed

1 IRON SUCROSE

Ferr ic Chlor ide is dissolved in wa ter and sodium bica rbona te solu t ion is added

to precipita te fer r ic hydroxide which is filt ered.

Above fer r ic hydroxide is mixed with sucrose and hea ted to get iron sucrose in

solu t ion . Which is concent ra ted to get th ick mass which is added with vigorous

st ir r ing to DNS and then methanol to precipita te iron sucrose solid. This is

cent r ifuged and slur r ied with DNS and acetone aga in to remove the impur it ies.

The wet materia l is dr ied under vacuum, pulver ized, redr ied, milled, blended as

needed and packed.

Raw material:

Ferric Chloride

Sodium carbonate

Sucrose

DNS denatured spirit

Methanol

Acetone

Raw m ateria l con su m ption per kg of ou tpu t

Ferric Chloride = 0.2 kg / kg

Sodium Carbonate = 0.04 kg / kg

Sucrose = 2 kg / kg

DNS = 8 L / kg

Methanol = 5 L / kg

Acetone = 1 L / kg

Annexures GCPL 17

P ROCESS FLOW CHART

Sodium carbona te

solu t ion

MLR collect ion

Hea t

DNS

MLR collect ion

methanol

DNS

Acetone MLR collect ion

Water + Ferric Ch loride

Filtration of Ferric

h ydroxide

Ferric h ydroxide Cake +

Su gar

Con cen trated

Filtration

Filte r Mass

Filtration

Vacu u m Dryin g

Millin g , Blen din g & P ackin g

Annexures GCPL 18

2. CALCIUM DOBESYLATE

Stage-I: Sulphur ic acid is a dded to a suspent ion of hydroquinone in ethylene di

ch lor ide. After the su lfona t ion , water is added and aqueous layer separa ted.

Stage-II: aqueous layer is neut ra lized with a slur ry of ca lcium carbona te in

wa ter , cent r ifuged to separa te ca lcium sulfa te.

Liquid from cent r ifuge is concent ra ted, ch illed, the product filt ered and washed

with isopropanol and dr ied.

Raw m ateria l:

Hydroquinone

Sulphuric acid

Calcium carbonate

Ethylene di chloride

Isopropanol


Hydroquinone = 1.2 kg

Sulphuric acid = 1.6 kg

Calcium carbonate = 1.6kg/kg

Ethylene di chloride = 4L/kg

Isopropanol = 2L/kg

Annexures GCPL 19

P ROCESS FLOW CHART

Stage -1

su lphur ic acid

layer separation

Stage -II

ca lcium carbona te

cen trifu ge

concen trated

ch illed

isopropanol

Hydroqu in on e + e th ylen e d i

ch loride

Aqu eou s layer

Liqu id from cen trifu ge

Crystallisation

Dryin g

Cen trifu gation


Residu e

Annexures GCPL 20

3. TIEMMONIUM METHYL SULPFATE (TMS)

Morpholine is reacted with 2-acetyl th iophene and p-formaldehyde in the

presence of hydrochlor ic acid in dena tured spir it (DNS) to get the cor responding

mannich base as HCl sa lt . The above HCl sa lt is basified in toluene to get the

corresponding mannich ketone base. This is reacted with phenyl magnesium

bromide in tet rahydrofuran to get t iemmonium hydrochlor ide which is pur ified

using methanol slur ry. The pure hydrochlor ide is conver ted to base and t rea ted

with dimethyl su lfa te in acetone to get the t iemmonium methyl su lfa te. This is

dr ied in a vacuum oven, milled, blended and packed.

Raw m ateria l:

Morpholine

2- Acetyl thiophene

P-Formaldehyde

Hydrochloric acid

Denatured spirit (DNS)

Phenyl magnesium bromide

Dimethyl Sulfate

Tetrahydrofuran

Methanol

Toluene

acetone


Morpholine = 1 kg / kg

2- Acetyl th iophene = 1.5 kg / kg

P-Formaldehyde =0.7 kg / kg

Hydrochlor ic acid = 5.7 kg / kg

Dena tured spir it (DNS) = 6L / kg

Phenyl magnesium bromide =2.3 kg / kg

Dimethyl Sulfa te =0.5 kg / kg

Annexures GCPL 21

Methanol = 3L/kg

Tetrahydrofuran = 2L/kg

Toluene = 8 L/kg

Acetone = 5L/kg

P ROCESS FLOW CHART

Con. HCl

Reflux

MLR collect ion

Phenyl magnesium bromide

Con. HCl

Methanol MLR collect ion

Dimethy su lpha te

MLR collect ion

Morph olin e + 2- Ace tyl

th ioph en e + P -Form aldeh yde

+DNS

Cool, Cen trifu gation ,

Bas ification

Keton e Base

Qu en ch in g ice w ater

Cen trifu gation

Basification w ith Am m on ia

Cen trifu gation

Vacu u m Dryin g

Annexures GCPL 22

4 ETHAMSYLATE

Stage-I: Sulphur ic acid is added to a suspent ion of hydroquinone in ethylene di

ch lor ide. After the su lfona t ion , water is added and aqueous layer separa ted.

Stage-II: aqueous layer is neut ra lized with diethylamine, concent ra ted, ch illed,

the product filt ered and washed with isopropanol and dr ied.

Raw m ateria l:

Hydroquinone

Sulphuric acid

Diethylamine

Ethylene di chloride

Isopropanol


Hydroquinone =0.8 kg/kg

Sulphuric acid = 1.5 kg/kg

Diethylamine = 1.6 L/kg

Ethylene di chloride = 2.3L/kg

Isopropanol = 0.5L/kg


Annexures GCPL 23

P ROCESS FLOW CHART

Stage -I:

Suphur ic acid

wa ter

layer separation

s tage -II

diethylamine

con cen tration

isopropanol

h ydroqu in on e + e th ylen e d i

ch loride

Su lph on ated m ass

Aqu eou s layer

Crystallisation

Dryin g

Cen trifu gation

Ch ill, re s idu e

Annexures GCPL 24

5 TOLPERISONE HCl

Mixture of 4-methyl propiophenone, piper idin e, and hydrochlor ic acid hea ted to

reflux in 1,3-dioxalone. After the react ion is over , dilu ted with ethyl aceta te and

chilled with st ir r ing. Product formed is cen t r ifuged, washed with ethyl aceta te.

The crude product is pur ified with methanol and ethyl a ceta te using charcoa l.

Raw m ateria l:

1.4-methyl propiophenone

2. piper idine

3.1,3-dioxalone

4. conc. hydrochlor ic acid

5. ethyl aceta te

6. methanol


1.4-methyl propiophenone 1.0 kg

2. piper idine 0.6 kg

3.1,3-dioxalone 1.5 kg

4. conc.hydrochlor ic acid 0.025 L

5. ethyl aceta te 3 L

6. methanol 1.0 L


Annexures GCPL 25

P ROCESS FLOW CHART

Reflux

ch ill

stage-1

charcoa l

filt er

4-m eth yl

propioph en on e+piperid in e+

HCl + 1,3-d ioxolan e

Dilu te w ith e th yl ac tate

Cen trifu gation

Dissolve s tage -1 in m eth an ol

cen trifu gation

Filtrate , con cen trate , add

e th yl ace tate , ch ill

Vacu u m dryin g

Annexures GCPL 26

6. a . CALCIUM GLYCEROP HOSP HATE

Stage – I: Epichlorohydr in is hydrolised with dilu te acid, and reacted with

Tr i sodium phospha te, to get Crude sodium Glycerophospha te.

Stage –II : To the Above crude Sodium Glycerophospha te solu t ion , Ca lcium

chlor ide is added to get Crude Ca lcium Glycerophospha te

Stage – III : crude Ca lcium Glycerophospha te is washed with DNS: Water

mixture to get Pure Ca lcium Glycerophospha te, which is cent r ifuged and dr ied.

Raw m ateria l:

1. Epichlorohydrin

2. Trisodium phosphate

3. Calcium chloride

4. Denatured spirit (DNS)


1. Epichlorohydrin =1.5 kg / kg

2. Trisodium phosphate = 6 kg / kg

3. Calcium chloride = 2 kg / kg

4. Denatured spirit (DNS) = 5L / kg


Annexures GCPL 27

P ROCESS FLOW CHART

Stage - I

Reflux

Hot condit ion

Stage -II

Calcium chlor ide

Stage -III

DNS: Water

Epichlorohydrin + water

Reaction w ith Trisodiu m

ph osph ate

Ch arcoal treatm ent &

Filtration

Reaction w ith calc iu m

ch loride

Dryin g

Cen trifu gation & Slu rry

w ash


Annexures GCPL 28

6.b. MAGNESIUM GLYCEROP HOSP HATE

Stage – I: Epichlorohydr in is hydrolised with dilu te acid, and rea cted with

Tr i sodium phospha te, to get Crude sodium Glycerophospha te.

Stage –II : To the Above crude Sodium Glycerophospha te solu t ion ,Magnesium

ch lor ide is added to get Crude Magnesium Glycerophospha te

Stage – III : crude Magnesium Glycerophospha te is washed with DNS: Water

mixture to get Pure Magnesium Glycerophospha te, which is cent r ifuged and

dr ied

.

Raw m ateria l:

4. Epichlorohydrin


6. Magnesium chloride



8. Epichlorohydrin =1.5 kg / kg


10. Magnesium chloride = 3 kg / kg

11. Denatured spirit (DNS) = 5L / kg

Annexures GCPL 29

P ROCESS FLOW CHART

Stage - I

Reflux

Hot condit ion

Stage -II

Magnesium chlor ide

Stage -IV

DNS: Water



ph osph ate

Ch arcoal treatm e nt &

Filtration

Reaction w ith Magn es iu m

ch loride

Dryin g


w ash

Con cen tration

Annexures GCPL 30

6. c . SODIUM GLYCEROP HOSP HATE

Stage – I: Epichlorohydr in is hydrolised with dilu te acid, and reacted with

Tr i sodium phospha te, to get Crude sodium Glycerophospha te solu t ion which is

concent ra ted and filt ered to get Crude sodium Glycerophospha te

Stage – II : crude Sodium Glycerophospha te is washed with DNS: Water

mixture to get Pure Sodium Glycerophospha te, which is en t r ifuged and dr ied

.

Raw m ateria l:

1. Epichlorohydrin




4. Epichlorohydrin =1 kg / kg


6. Denatured spirit (DNS) =5L / kg


Annexures GCPL 31

P ROCESS FLOW CHART

Stage - I

Reflux

Hot condit ion

DNS

Stage -II

DNS: Water



ph osph ate

Ch arcoal treatm ent &

Filtration

Crysta llisation

Dryin g


w ash

Con cen tration

Annexures GCPL 32

7 FENSPIRIDE HYDROCHLORIDE

MANUFACTURING FLOWCHART:

Stage -1:

1-(2-ph en yle th yl)-4-p iperidon e

Hydroch loric ac id

Water, ce n trifu ge , dry

S tage -II : Fen spiride Hydroch loride Cru de

Zin c Du st

bas ify w ith Aq. am m on ia

Dich lorom eth an e

Con cen tration

Toluen e , Die th y l carbonate

w ater, to lu en e

ac id ify ,

Hydroch loric ac id

cool, cen trifu ge , dry


Nitrom eth an e+ DMSO +

P otass iu m Carbon ate , 0 deg .C

Stage -1

Meth an ol + Stage -1+

Hydroch loric ac id , <5 deg .C

Dich lorom eth an e layer

to lu en e layer

Stage -II

Res idu e

Annexures GCPL 33

S tage -III: P u rification

S tage -II

Heat

Ace ton e

Cool & Cen trifu ge ,

Man u factu rin g process for th e Fen spiride Hydroch loride :

Stage -I: 4-(n it romethyl)-1-phenethylpiper idin -4-ol is prepared by react ing 1-(2-

phenylethyl)-4-piper idone with n it romethane and potassium carbona te in

dimethylsu lfoxide. stage-1 is isola ted by quenching in wa ter Cent r ifuging.

Stage -II: Fenspir ide hydrochlor ide crude is prepared by the reduct ion of

stage-I with zinc dust and hydrochlor ic acid, basifica t ion with aqueous

ammonia and ext ract ing with dich loromethane. Dichloromethane ext ract is

concent ra ted to get 4-(aminoethyl)-1-phenylpiper idin -4-ol, which is reacted

with diethylca rbona te in the presence of sodium methoxide to get Fenspir ide

base. This is t rea ted with Hydrochlor ic acid to get Fenspir ide hydrochlor ide

crude.

Stage -III: Fenspir ide HCl crude dissolved in methanol , t rea ted with Act ivated

ca rbon . filt ered, filt ra te concent ra ted completely, Acetone is added , solid

cent r ifuged, dr ied under vacuo <60 deg.C , milled ,sieved and packed.

Meth an ol

Con cen trate

Dryin g, m illin g , S ievin g+

packin g

Annexures GCPL 34

8 CLOZAPINE :

MANUFACTURING FLOW CHART

2-ch loro ben zoic ac id

reduct ion

wa ter +sodium dith iona te

s tage -1

cyclisa t ion , xylene

s tage -2

N-m eth ylp iperazin e , TiCl4

s tage -3

recrysta llisation

Brie f process description : Stage -1:

4-chloro-2-n it ro an iline is reacted with 2-chloro bezoic acid and th e resu lt ing

product is reduced in -situ with sodium dithiona te in wa ter to get 2-( 4-ch loro

-2-am in o d iph en ylam in o)ben zoic ac id s tage -1

S tage -2:

Stage-1 is cylised in refluxing xylene to get 8-ch loro-5H-ben zo-

[b,e ][1,4]d iazepin e -11-10H-on e

Stage -3:

4-ch loro-2-n itro an ilin e

+potass iu m carbonate

+DMF

2-( 4-ch loro -2-am in o

d iph en ylam in o)benzoic ac id

8-ch loro-5H-ben zo-

[b,e ][1,4]d iazepin e -11-10H-on e

cru de c lozapin e

pu re c lozapin e

Dryin g, s iev in g an d

packin g

Annexures GCPL 35

Stage-2 is reacted with N-methyl piperazine in presence of t it an ium

tet rachlor ide to get crude clozapine (stage-3)

Stage -4: pu re c lozapin e

Crude clozapine is pur ified to pure clozapine by dissolving in methanol ,

charcolising, filt er ing, concent ra t ing and cooling. The product is cent r ifuged,

dr ied under vacuum below 60 deg.C , milled , sieved and packed.

9 NIFUROXAZIDE MANUFACTURING FLOW CHART:

Syn th es is of Nifu roxazide :

Nitrofu rfu ral d iace tate

Heat

4-hydroxy benzohydrazide

Hydroch loric ac id

Heat & Cool

Cen trifu ge

Meth an ol

Cen trifu ge

Man u factu rin g procedu re for Nifu roxazide :

Nit rofufura l Diaceta te reacts with 4-hydroxy benzohydrazide in the presence of

su lfur ic acid in DNS to form the Nifuroxazide.

Water +Su lph uric ac id+

DNS

Reaction m ass

Reaction m ass

Wet cake , re flu x

Dryin g, m illin g , s iev in g,

packin g

Annexures GCPL 36

10 OXETACAINE MANUFACTURING FLOW CHART:

Stage -I:

Su lfu ric ac id

wa ter

Cen trifu ge , dry

S tage -II: Methyla t ion

Dim eth yl su lfate

P otass iu m h ydroxide

Heatin g

Water

Extraction & Disti llation

Stage -III:

P EG-400

h eatin g Sodiu m Hydroxide

d ich loro e th an e

Water

Extraction

Layer separation

Ch loroace ty l ch loride

Sodiu m h ydroxide

Extraction & Disti llation

Dimethyl benzyl carbinol +

Acetonitrile

S tage -I+ Tolu en e

Dim et

s tage -1

Reaction Mass

Res idu e

Stage -II

Reaction Mass

Organ ic layer

Res idu e

Annexures GCPL 37

S tage -IV: Oxetaca ine crude

Etan ol am in e Tolu en e

Sodiu m Hydroxide

Heatin g

Water

Extraction , layer separation

Hydroch loric ac id


Am m on ia

Cen trifu ge , dry

S tage -V: Purifica t ion

Isopropyl a lcoh ol

Water

Cen trifu ge

Man u factu rin g P rocess of Oxe tacain e :

S tage -1: Dimethyl benzyl ca rbinol is reacted acetonit r ile and su lfur ic acid to

get stage-I.

Stage -I1: Stage-I methyla ted with dimethyl su lfa te in the presence of

potassium hydroxide in toluene to stage-II.

Stage -II1: Stage-II hydrolyzed with sodium hydroxide and reacted with

ch loroacetyl ch lor ide to stage-III.

Stage -IV: Stage-III react ed with ethanol amine in the presence of sodium

hydroxide in toluene to stage-IV (Oxetaca ine crude).

Stage -V: Oxetacine crude crude pu r ified using Isopropyl a lcohol and water to

get pure Oxetaca ine

Residu e

Reaction

Organ ic layer

Acid ic layer

s tage -IV

Stage -IV


packin g

Annexures GCPL 38

11 BENFOTIAMINE

Mixture of th iamine HCl and or thophosphor ic acid is hea ted and phosphorous

pentoxide is added slowly over a per iod. Dilu ted by a dding wa ter and

Hydrolysed by hea t ing to reflux

The above solu t ion is basified with sodium hydroxide and t rea ted with benzoyl

ch lor ide in methylene di ch lor ide a t low tempera ture. After the react ion ,

cent r ifuged to remove inorganics, the MLR is concent ra ted and filt ered. The

filt ra te is acidified to get the crude benfot iamine which is cent r ifuged and

washed with water .

crude product is dissolved in dilu te sodium hydroxide, charcolised, filt ered,

acidified to get the pure product which is cent r ifuged, washed with wa ter ,

methanol and spin dr ied. The wet mater ia l is dr ied under vacuum, pulver ized,

milled, blended as needed and packed.

Raw m ateria l:

1. th iamine HCl

2.or thophosphor ic acid

3.phosphorous pentoxide

4.Sodium hydroxide

5.benzoyl ch lor ide

6.Hydrochlor ic acid

7.methylene ch lor ide

8.methanol


1. th iamine HCl 2.5 kg

2.or thophosphor ic acid 3.5 kg

3.phosphorous pentoxide 2.5 kg

4.Sodium hydroxide 2.5 kg

5.benzoyl ch lor ide 1.5 kg

6.Hydroch lor ic acid 2.5 L

7.methylene ch lor ide 5.0 L

Annexures GCPL 39

8.methanol 2.0 L

P ROCESS FLOW CHART

Phosphorous pentoxide

hea t

wa ter

reflux, cool

benzoyl ch lor ide

in DCM

hydrochlor ic acid

Hydrochlor ic acid

Th iam in e HCl +

orth oph osph oric acid

Reaction m ixtu re

Reaction m ixtu re+ sodiu m

h ydroxide

Cen trifu gation

Cen trifu gation


Above so lid + aq. sodiu m

h ydroxide

Ch arcoalise , fi lte r

Cen trifu ge , MLR con cen trate

Vacu u m dryin g

Annexures GCPL 40

12 CALCIUM FOLINATE

Folic acid dissolved in wa ter and t rea ted with sodium borohydr ide under

cooling. The mixture is quenched in to hydrochlor ic acid and then formyla ted

using formic acid. The react ion solu t ion is concent ra ted under vacuum and

cent r ifuged to get stage-1(formyl folic acid). Stage-1 is reacted with

t r iethylamine in wa ter and then conver ted to the cor responding ca lcium sa lt

using ca lcium chlor ide. The product is precipita ted by adding DNS. The crude

product is pu r ified using water and DNS. Washed with acetone and dr ied. The

wet product is dr ied under vacuum, milled and sieved and packed.

Raw m ateria l:

1. folic acid

2. sodium borohydr ide

3. conc. HCl

4. t r iethyl amine

5. ca lcium chlor ide

6. DNS

7.acetone

8.formic acid

9. Methanol


1. folic acid 2.5 kg

2. sodium borohydr ide 5 kg

3. conc. HCl 7 L

4. t r iethyl amine 2 L

5. ca lcium chlor ide 2 kg

6. DNS 75 L

7.acetone 5 L

8.formic acid 70 L

Annexures GCPL 41

9. methanol 5L

P ROCESS FLOW CHART

Sodium boro hydr ide

Formic acid

Stage -1

t r iethylamine

DNS

ca lcium chlor ide

Qu en ch in to HCl

Filtration , con cen tration

Ce n trifu gation

Stage -1 in w ater

Dryin g u nder vacuu m

Millin g , s iev in g Blen din g &

P ackin g

Reaction m ixtu re

cen trifu gation

recrysta llisation

cen trifu gation

Folic ac id in w ater

Annexures GCPL 42

13. TRIMETAZIDINE HYDROCHLORIDE

Stage -I: Synthesis of Tr imetazidine Hydrochlor ide crude

P iperazin e

5% P alladiu m on Carbon

Hydrogen ator

Centrifu ge , Con cen trate

Tolu en e ,w ater


isopropan olic HCl,cool

Centrifu ge , dry

S tage -II: Purifica t ion of Tr imetazidine crude

Meth an ol

ac tivated carbon

h eat, fi lte r

concen trate

Ace ton e

Cen trifu ge

Man u factu rin g procedu re for Trim etazid in e Hydroch loride :

Stage -I: 2,3,4-t r imethoxy benza ldehyde and piperazine is condensed and

reduced using Pa lladium on ca rbon and Hydrogen gas and isola ted as ,

t r imetazedine hydrochlor ide crude

2,3,4-trim eth oxy

ben zaldeh yde

+ Meth an ol

Reaction m ass

Res idu e

Tolu en e Layer

S tage -I

Stage -I

fi ltrate

Res idu e

Dryin g, Millin g , S ievin g,

packin g

Annexures GCPL 43

Stage -II: Stage-I pur ified by dissolving in methanol, charcolisa t ion , filt ra t ion ,

concent ra t ion . pure Tr imetazidine hydrochlor ide. is isola ted by adding acetone.

14 CALCIUM METHYLFOLATE


Stage -I: Synthesis of Ca lcium Methylfola te crude

Sodiu m Hydroxide

sodiu m boroh ydride

ac id ification , cen trifu gation

Sodiu m Boroh ydride

Form aldeh yde

ac id ification , cen trifu gation

Calc iu m ch loride

Cen trifu gin g ,dryin g

S tage -II: P u rification of Calc iu m m ethylfo late :

Water

h ydroch loric ac id ,

Cen trifu ge

Sodium h ydroxide

Calc iu m ch loride

ca lc iu m ch loride

Cen trifu ge

Stage -I

so lid +w ater

P rocess w ater+ Folic ac id

Cen trifu gate


packin g

Cen trifu gate

crude CaMeF

Annexures GCPL 44

Man u factu rin g process for Calc iu m meth ylfo late :

Stage -I: A solu t ion of Folic acid in sodium hydroxide is reduced with Sodium

borohydr ide to get tet rahydrofola te, which is reacted with formaldehyde and

reduced aga in with sodium borohydr ide and then t rea ted with ca lcium

chlor ide to get Calcium methylfola te crude.

Stage -II: m eth yl fo lic ac id is prec ip itated by ac id ification of th e cru de

produ ct w h ich is redisso lved in Sodium hydroxide, charcoa lised, filt ered

and reprecipita ted as pure ca lcium methyl fola te by adding filt ered ca lcium

chlor ide solu t ion .

15 UBIQUINOL ACETATE

MANUFACTURING FLOWCHART: Pyridine , Zinc Dust Acetic Anhydride Cooling, acidification, n-heptane, layer separation concentration DNS Centrifuge Manufacturing Procedure of Ubiquinol acetate: Coenyme Q10 reduced with Zinc dust in the presence of Hydrochloric acid, reacted with acetic anhydride to get Ubiquinol acetate, which is extracted with n-heptane and isolated by addition of DNS.

Coen zym e Q10

n- heptane layer

residue

Drying, Milling, sieving, Packing

Annexures GCPL 45

16. STRONTIUM RANELATE

Stage-I: ethyl acetone dica rboxila te is made by react ing cit r ic acid with

ch lorosulfonic acid in methylene ch lor ide

Stage – II: ethyl acetone dica rboxila te is condensed with , Malano n it r ile and

Sulphur in presence of t r iethylamine to get stage-II

Stage –III: Stage –II is reacted with Methyl bromoaceta te and Potassium

carbona te in Acetone, and to get a lkyla ted Stage –II.

Stage –IV; Stage –III reacted with st ront ium hydroxide in wa ter under reflux

condit ion to get the fina l product which is washed with wa ter , dr ied, milled and

packed.

Raw m ateria l:

Triethylamine/Morpholine,

Methanol,

Malano nitrile

Sulphur

Acetone,

Potassium carbonate and

Methyl bromoacetate

Strontium hydroxide

isopropanol


Citric acid = 2 kg / kg

Chlorosulphonic acid = 2kg / kg

Methylene dichloride =2 L / kg

Morpholine = 1.8 kg / kg

Methanol = 8 L / kg

Malano nitrile = 0.6 kg / kg

Isopropanol = 2L/kg

Suphur = 0.2 kg / kg

Acetone = 8 L / kg

Potassium carbonate = 1.2kg / kg

Methyl bromoacetate = 1.3 kg / kg

Strontium hydroxide = 1.5 kg / kg

Annexures GCPL 46

P ROCESS FLOW CHART

Stage - I

Cit r ic acid

Water

Stage - II

Hot condit ion

Water

Stage -III

Hot condit ion

Methylene dichloride +

Chlorosulphonic acid

Qu en ch in g

Morph olin e + m ethan ol +

Malan o n itrile + Suph u r

Qu en ch in g

Ace ton e + P otass ium

carbon ate + Meth yl

brom oace tate

Filtration

Filtration & Con cen tration

Annexures GCPL 47

Stage -IV

Water

Hot condit ion

17. P HENYRAMIDOL HYDROCHLORIDE

Stage -1: Synthesis of Phenyramidol Hydrochlor ide crude

Styre n e Oxide

Water + Eth yl ace tate


IP A.HCl

Cen trifu ge

2-Am in opyrid in e +DMF + Lith iu m

am ide

Reaction mass

Organ ic layer

P h en yram idol Hydro ch loride cru de

s tage -1

Reaction w ith s tron tiu m

h ydroxide

Dryin g

Filtration


Annexures GCPL 48

S tage -2 :Pure Phenyramidol Hydrochlor ide

Heatin g , fi ltration

Distillation

Aceton e

Man u factu rin g process for P h en yram idol h ydroch loride :

Stage -I: 2-Amino pyr idine reacts with styrene oxide in the presence of lith ium

amide to form the Phenyramidol hydrochlor ide crude.

Stage-II: Phenyramidol hydrochlor ide pur ified by using recrysta llisa t ion using

methanol and acetone to get pure Phenyramidol hydrochlor ide.

Meth an ol + Stage -1+activated

carbon

fi ltrate

Cen trifu gation , dryin g,

m illin g s iev in g & packin g

Res idu e

Annexures GCPL 49

18 IRON SORBITOL COMPLEX


citric acid

basification with Sodium Hydroxide

Ferric Chloride

filter, adjust pH with Citric acid

DNS DNS

Procedure: a solution Sorbitol , dextrin and citric acid in water is heated and complexed

with Ferric chloride solution in the presence of sodium hydroxide. pH is adjusted with

citric acid , filtered . the complex is isolated by adding DNS. which is centrifuged and dried

Sorbitol + Water+dextrin

Reaction Mass

Filtrate

Centrifuge

Drying, Milling, Sieving, Packing

Annexures GCPL 50

19 NAFTIFINE HYDROCHLORIDE:

Stage -I: Naft ifine hydrochlor ide crude

Cin n am yl Ch loride

Heat, cen trifu ge

Hydroch loric ac id

Cen trifu ge , dry

Stage -II: Purifica t ion of Naft ifine hydroch lor ide

Cen trifu ge , con cen trate

Isopropyl a lcoh ol

cool, Cen trifu ge

Man u factu rin g P rocedu re for Naftifine Hydroch loride .

Stage -I: N-Methyl –naphthyl- methanamine reacted with Cinnamyl ch lor ide in

the presence of sodium bica rbonate in toluene to get Naft ifine hydrochlor ide

crude.

S tage -II: Stage-I pur ified by dissolving in methanol, charcolisa t ion , filt ra t ion

concent ra t ion and isopropyl a lcohol added to get Naft ifine hydrochlor ide.

N-Meth yl –n aph th yl

m eth an am in e

+Sodiu m Bicarbonate+ Tolu en e

Stage -II + Meth an ol+activated

carbon

s tage -1

re s idu e

Dryin g, Millin g ,

s iev in g

cen trifu gate

Annexures GCPL 51

20 ESMOLOL HYDROCHLORIDE MANUFACTURING FLOWCHART:

Stage-I

Malonic acid Heat Water Stage-II: hydrogen gas sulphuric acid concentration Stage-III: Sodium Hydride Epichlorohydrin Water , Ethyl acetate layer separation, concentration Stage-IV

Isopropylamine Concentration

Ethyl acetate, HCl filtration

Stage-V:

Ethyl acetate Acetone

Crystallization

4-Hydroxy benzaldehyde +

Pyridine

Reaction Mass

Centrifuge and Drying

Stage-I +

5% Pd/C + methanol

stage-II

Stage-II +

Dimethylformamide

Reaction

stage-III

Stage-III+ Methanol

Stage-IV

Esmolol Hydrochloride Centrifuge, Drying, Packing

Esmolol Base

Esmolol Hydrochloride

Crude

Annexures GCPL 52

Manufacturing procedure of Esmolol Hydrochloride:

Stage-I : 4-hydroxy benzaldehyde condensed with malonic acid in the presence of

pyridine to give the 3-(4-hydroxyphenyl)acrylic acid (Stage-I).

Stage-II : Stage-I reduced with Hydrogen and Pd/C to get 3-(4-

hydroxyphenyl)propanoic acid . Which is esterified with methanol to get

methyl-3-(4-hydroxyphenyl)propanoate (Stage-II).

Stage-III : Stage-II condensed with Epichlorohydrin in the presence of sodium

hydride to get methyl-3-[4-(3-chloro-2-hydroxypropoxy)phenyl]

propanoate (Stage-III).

Stage-IV : Stage-III condensed with isopropyl amine to get Esmolol base, which is

treated with hydrochloric acid to get Esmolol hydrochloride

Stage-V : Stage-IV is re crystallised from ethyl acetate and acetone to get pure

Esmolol Hydrochloride.

21 CALCIUM L-5- METHYLTETRAHYDROFOLATE MANUFACTURING

FLOW CHART:

Stage -I: Synthesis of Ca lcium Methylfola te

Sodiu m Hydroxide

Dissolu tion

con c . HCl Sodiu m boro h ydride

Cen trifu ge

Form aldeh yde

Sodiu m Boroh ydride

acidify Conc.HCl

Cen trifu ge

Calc iu m ch loride

Centrifu ge

P rocess w ater+ Folic ac id

Filtrate

Reaction m ass

F iltrate

s tage -1

Annexures GCPL 53

Stage -II: Synthesis of Methylfola te sa lt with S-phenylethylamine

Hydroch loric ac id

Cen trifu ge

Water

S-ph en yl e th yl am in e

Centrifu ge

DNS

Cen trifu ge , dry

S tage -III: Synthesis of Ca lcium -L-Methylfola te Crude:

L-Cyste in e

Cen trifu ge

DNS, Ace ton e

Centrifu ge ,dry

Step-IV: Pur ifica t ion of Ca lcium -L-methylfola te:

Water

Heatin g & Coolin g

Man u factu rin g proces s for th e preparation of Calc iu m L-Meth ylfo late :

Stage -I: a solu t ion of Folic acid in sodium hydroxide is reduced using Sodium

borohydr ide to t et rahydrofola te ,which is reaced with formaldehyde to get

Stage -1

Wet Cake

P roduct (w e t

cake )

s tage -II

S tage -II + Water + DNS

Reaction m ass

Wet Cake

s tage -III

S tage -III

Reaction

Dryin g, m illin g , S ievin g, P ackin g

Annexures GCPL 54

5,10- methyene tet rahydrofola te th is is hydrolysed and reduced by sodium

borohydr ide to get Ca lcium DL- methylfola te.

Stage -II: Calcium DL- methylfola te reacted with S-phenyl methylamine to get

the S sa lt .

Stage -III: a solu t ion of The above amine sa lt is t rea ted with ca lcium chlor ide

to get L-methyl fola te crude Stage -IV: Calcium L-Methylfola te crude is

pur ified in wa ter to get pure Ca lcium L-methyl fola te.

22 MINOXIDIL:

P ROCESSES FLOW CHART

Stage -I: Prepara t ion of Urea Hydrogen peroxide adduct

Urea

cool, cen trifu ge

Stage -II : Prepara t ion of n -Oxide

a ) P reparation of cata lyst so lu tion

S tage -I addition

b) P reparation of n -Oxide

Ca ta lyst solu t ion

Cen trifu ge

Water+ Hydrogen peroxide

Stage-I

Carbin ol+ P hth alic

an h ydride

Catalyst so lu tion

Carbin ol +2,4 d iam in o-6-

ch loropyrim idin e

Stage -II

cen

Annexures GCPL 55

S tage -III: Prepar ion of Minoxidil crude

Dis t i lation

Coolin g & Centrifu ge

S tage -IV: Purifica t ion

Heatin g

Coolin g & Cen trifu ge

Man u factu rin g procedu re of Min oxid il:

Stage -I: P reparation of Urea Hydrogen peroxide adduct

Hydrogen peroxide (50%) reacts with urea to form the urea hydrogen peroxide

adduct .

Stage -II: P reparation of n -Oxide

a) The ca ta lyst solu t ion is prepared by the react ion of urea hydrogen peroxide

adduct and phtha lic anhydr ide in ca rbinol.

b) The above ca ta lyst solu t ion is added to a solu t ion of 2,4 diamino-6-

chloropyr imidine in ca rbinol and warmed. The precipita ted oxide is cooled and

cent r ifuged.

Stage -III: P reparation of Min oxid il cru de

Minoxidil crude is prepared by react ing Piper idine with stage-II a t 60-70 deg C.

Product was isola ted by cent r ifuga t ion.

Stage -IV: P u rification of Min oxid il crude

P iperid in e + Stage -II

Min oxid il cru de +

Meth an ol

Reaction m ass

Stage -III

Dryin g, m illin g , s iev in g &

packin g

Annexures GCPL 56

Minoxidil Crude pur ified by using ca rbinol to get pure Minoxidil.

23 MEBEVERINE HYDROCHLORIDE MANUFACTURING FLOWCHART:

STAGE-I:- Synthesis of 4-bromobutyl-3,4-dimethoxybenzoa te

1,4-Dibrom obu tan e

High vaccu m dis ti llation

STAGE-II: Synthesis of Mebever ine Hydrochlor ide crude

Meth yl isobu tyl

ke ton e

P otass iu m carbonate

Heat an d fi lte r

Water layer separa t ion ,

concent ra t ion

Cent r ifuge IP A. HCl

STAGE-III: Purifica t ion

Meth yl

isobu tyl ke ton e

filt er ,concent ra te and cent r ifuge

Veratric ac id +

P otass iu m

Hydroxide

1-(4-m eth oxyph en yl)-2-

e th ylam in opropan e

+

MBH-Stage -I

fi ltrate

residue

Mebeverin e

Hydroch loride Crude

Mebeverin e

Hydroch loride Crude

+activated carbon

P ackin g, Dryin g, Millin g , S ievin g

Stage -I

https://en.wikipedia.org/wiki/Methyl_isobutyl_ketone






Annexures GCPL 57

Man u factu rin g P rocedu re for Mebeverin e Hydroch loride :

Stage -I : Vera t r ic acid reacts with 1,4-dibromocompound in the presence of

potassium hydroxide to for m the 4-bromobutyl-3,4-dimethoxybenzoa te.

Stage -II : Stage-I reacts with 1-(4-methoxyphenyl)-2-ethylaminopropane in the

presence of sodium ca rbona te in Methyl isobutyl ketone to form the

Mebever ine Hydrochlor ide crude.

Stage -III: Stage-II pur ified by Methyl isobutyl ketone to get pure Mebever ine

Hydrochlor ide.

24 TERBINAFINE HYDROCHLORIDE:

Stage -I: Terbinafine hydrochlor ide crude

Ch loro-6,6-d im eth yl-2-h epten -4-yn e

Heat, cen trifu ge

Hydroch loric ac id

cen trifu ge , dry

S tage -II: Purifica t ion of Terbinafine hydrochlor ide

Cen trifu ge , con centrate

cool, Centrifu ge

Man u factu rin g P rocedu re for Terbin afin e Hydroch loride .

Stage -I: N-Methyl –naphthyl- methanamine reacted with 1-Chloro-6,6-

dimethyl-2-hepten-4-yne in the presence of sodium carbona te in toluene to get

t erbinafine hydrochlor ide crude.

S tage -II: Stage-I pur ified by dissolving in methanol, charcolisa t ion , filt ra t ion

concent ra t ion and isopropyl a lcohol added to get t erbinafine hydrochlor ide.

N-Meth yl –n aph th yl

m eth an am in e

+Sodiu m carbon ate+ Tolu en e

Stage -II + isopropan ol +activated

carbon

s tage -1

re s idu e

Dryin g, Millin g , s iev in g

cen trifu gate



Annexures GCPL 58

ANNEXURE – III DETAILS OF STORAGE OF

SOLVENT

Annexures GCPL 59

There are no dust emissions from the plant or process operation.

The source of fugitive emission will be from the storage tank of solvents, and leakages

from reactor.

Each reactor will connected to 2-consecutive condensers for recovery of solvent residue.

The Reactors after condenser will be connected to a Scrubber of 4000 m³/hr capacity.

Solvent will be absorbed in water and water + Solvent mixture are taken to stripper to

separate the solvent and water.

All Underground tanks vent are connected through 25NB pipeline to 1m² condenser with

chilled water coolant 15°C, condensed solvent are collected in a receiver. Mixed solvent

are taken for process based on suitability.

Stored solvents are non-volatile which are having high Boiling point (>65°C) and vapour

pressure is also very less.

Annexures GCPL 60

ANNEXURE – IV WATER BALANCE &

EFFLUENT MANAGEMENT

Annexures GCPL 61

Water Balan ce Diagram

All Values are in KLD Existing [ ] Proposed ( )

Evapora tion [14.0] + (7.5) = 21.5

Waste w ate r [34.0] + (24.5) = 58.5

Evaporation [7.5] + (12.0) = 19.5

Waste w ate r [4.5] + (6.5) = 11.0

Evaporation [1.0] + (1.2) = 2.2

Waste w ate r [4.0] + (4.8) = 8.8

Tre ate d Dom e stic Se w age [4.0] + (4.8) = 8.8

P e rm e ate Re cycle d w ate r [30.5] + (24.8) = 55.3

RO Re je ct Re cycle d w a te r [7.5] + (5.9) = 13.4

[65.0] + (56.5) = 121.5

Cooling / Boiler Make-up [12.0]+(18.5) = 30.5

Process/ Floor wash / Equipment Cleaning [48.0] + (32.0) = 80.0

Domestic Consumption [5.0] + (6.0) = 11.0

Garden [4.0] + (4.8) = 8.8

ETP [38.5] + (31.0)

= 69.5

RO

SIPCOT

[27.0] + (25.8) = 52.8

ME

[3

0.5

] +

(2

4.8

) =

5

5.3

Crystalization

/ Handling /

Evaporation

0.8

[8

.0 +

(6

.2) =

1

4.2

[38.0] + (30.7) = 68.7

STP

Annexures GCPL 62

ETP Diagram – Existing

Annexures GCPL 63

ETP Diagram - Proposed

Annexures GCPL 64

Annexures GCPL 65

The process of treatment of Trade Effluent

At GCPL (Unit III), trade effluent is generated from the floor washings and

equipment cleaning. The total quantity of this trade effluent generated upon

expansion will be 69.5 KLD. Existing trade effluent of 38.5 KLD is treated in the

existing ETP/RO/MEE and reused in the process. Proposed additional quantity of

generation of trade effluent of 31 KLD will be treated in proposed ETP/RO/MEE

and reused in process.

The trade effluent generated from floor washings/equipment cleanings is

collected in a collection tank.

At the inlet of the tank, hydrated lime slurry is added to effect neutralisation.

The neutralised waste is then pumped to flow control tank, from where the

waste is allowed to discharge into a settling tank.

The overflow from the settling tank is allowed to pass through a three stage

anaerobic contact filter.

After anaerobic treatment, the waste is aerobically treated in an aerated lagoon.

The treated wastewater from the lagoon is allowed to settle in a settling tank

and is pumped to aerated lagoon II, wherein polyelectrolyte is added for better

floc formation to enable easy settling of suspended particles.

The aerated water is then taken to settling tank II, from where the clear

supernatant is pumped into the collection tank.

The treated water is then passed through the RO plant. Treated water from RO

is reused and the RO rejects are subject to Mechanical evaporation. Condensed

water from Mechanical evaporator is also reused.

Upon expansion the Domestic sewage of 8.8 KLD will be treated in STP and

reused for greenbelt development within the plant premises.

Annexures GCPL 66

ANNEXURE – IV SOLID WASTE MANAGEMENT

Annexures GCPL 67

SOLID WASTE

Sl. No. Type of Solid Waste Quantity TPA

Disposal/Treatment

Existing

1. Spent catalyst / spent carbon 2.0 Stored in HDPE Bags used for

Common Landfill-TSDF

2. Chemical sludge from waste

water treatment

0.5 Stored in HDPE Bags used for

Common Landfill-TSDF

3. Used/spent oil 0.2 Recover and Reuse-CPCB

Authorized recyclers

Proposed Expansion

1. Ash from Boiler 200 Sold to brick manufactures

2. Chemical sludge from waste

water treatment plant

3.0 Stored in HDPE Bags used for Common Landfill

3. Concentration or evaporation

residues

105 Stored in HDPE Bags used for Common Landfill

4. Process Residue and wastes 145 Stored in HDPE Bags used for Common Landfill

5. Spent Solvent 30 Authorized recyclers

Wastes from the production process are collected and stored in closed containers. The

containers containing the waste is stored in a closed shed. The waste is disposed to

common waste collection yard of Tamil Nadu Waste Management Limited at

Gummidipoondi, Thiruvallur District.

Annexures GCPL 68

ANNEXURE – VI RAW MATERIAL

Annexures GCPL 69

Raw Materials

Existing List of Raw Materials including chemicals, Catalysts & Additives

S.

No Description Total (T/Year)

1 Dextrose Mono Hydrate 500

3 Gluconic acid/Glucono Delta Lactone 2000

4 Potassium (Bi)Carbonate 12

5 Calcium Carbonate 344

6 Sodium (Bi) carbonate 42

7 Zinc Carbonate/ Zinc Oxide 18

8 Magnesium Carbonate/Oxide 100

9 Manganese Carbonate/ Oxide 6

10 Lactic acid 250

11 Calcium Gluconate 60

12 Calcium Lactobionate 15

13 Calcium Lactate 72

14 Denatured Spirit 220

15 Lactose 100

16 Boric acid 2

18 Ferrous Sulphate/Iron Powder 50

19 Orotic acid 48

20 Citric acid 400

21 Pyro Glutamic acid 15

22 L- Aspartic acid 15

23 Ascorbic acid 30

24 Glycine 10

25 Nitric acid 50

26 Calcium Nitrate 25

27 Hydrogen Per oxide 10

28 Sulphuric acid 6

29 Tri Sodium Pyro Phosphate 30

Annexures GCPL 70

Proposed List of Raw Material

Sl. No. Raw Material kgs/ Annum State

1 Ferric Chloride 4100 Solid

2 Sodium Carbonate 320 Solid

3 Sucrose 16000 Solid

4 Hydroquinone 7400 Solid

5 Sulphuric Acid 9500 liquid

6 Calcium carbonate 4800 Solid

7 Marpholine 5000 liquid

8 2-Acetyl Thiophene 4800 liquid

9 HCl 16800 liquid

10 Phenyl Magnesium bromide 1500 liquid

11 P-Formaldehyde 3000 liquid

12 Dimethyl Sulphate 500 Solid

13 Diethylamine 1200 liquid

14 4-Methylpropiophenone 2000 liquid

15 Piperidine 1700 liquid

16 1,3 dioxolone 3000 liquid

17 Epichlorohydrin 4200 liquid

18 Trisodium phosphate 11000 Solid

19 Calcium Chloride 3300 Solid

20 Magnesium Chloride 1000 Solid

21 Thiamine HCl 15000 liquid

22 Orthophophoric acid 15000 liquid

23 P2O5 15000 liquid

24 Sodium Hydroxide 21000 Solid

25 Benzoyl Chloride 9000 liquid

26 Folic acid 2000 Solid

27 Triethylamine 2000 liquid

28 citric acid 2300 liquid

29 Chlorosulphonicacid 800 liquid

30 methylne dichloride 800 liquid

31 Morpholine 400 Solid

32 Suphur 200 Solid

33 potassium carbonate 200 Solid

34 Methylbromoacetate 400 liquid

35 strontium hydroxide 200 Solid

36 malano nitrile 200 liquid

37 Nitromethane 3600 liquid

38 DMSO 2400 liquid

39 Pottasium carbonate 1800 Solid

40 Zinc dust 1500 Solid

41 Ammonia 800 liquid

42 Sorbital 2000.0 liquid

43 Dextrin 1500.0 Solid

44 N-Methyl -naphthyl methanamine 1600.0 liquid

45 Sodium bicarbonate 800.0 Solid

46 Cannamyl chloride 600.0 Solid

Annexures GCPL 71

47 Activated carbon 5000 Solid

48 Hyflo 5000 Solid

49 Nitrofurfural diactate 5400 Solid

50 Hydroxy benzohydrazide 4500 Solid

51 Dimethyl benzyl carbinol 500 Liquid

52 Dimethyl sulphate 300 Solid

53 Pottasium hydroxide 500 Solid

54 PEG-400 100 Liquid

55 Chloroacetyl chloride 200 Solid

56 2-Aminopyridine 2400 Liquid

57 Lithium 1550 Solid

58 styrene oxide 1500 Solid

59 IPA-HCl 2000 Liquid

60 2,3,4- trimethoxy benzaldehyde 3000 Liquid

61 Piperazine 1250 Liquid

62 5% palladium on carbon 1500 Solid

63 Isoproponolic acid 1800 Liquid

64 Coenzyme-Q10 1200 Solid

65 Acetic anhydride 1640 Liquid

66 N-heptane 200 Liquid

67 4-Hydroxy benzaldehyde 600 Liquid

68 Pyridine 250 Liquid

69 malonic acid 300 Solid

70 hydrogen gas 200 Gas

71 Dimethyl formamide 200 Liquid

72 Isopropalamine 300 Liquid

73 Folic acid 1200 Solid

74 sodium borohydride 600 Solid

75 Formaldehyde 400 Liquid

76 S-Phenylethyl amine 140 Liquid

77 Hydrogen peroxide 5200 Liquid

78 Urea 4550 Solid

79 phthalic anhydride 3900 Liquid

80 2,4 diamino-6- chloropyrimidine 2600 Liquid

81 Piperdine 1300 Liquid

82 Veratric acid 3000 Liquid

83 1,4 Dibromobutane 2000 Liquid

84 Potassium hydroxide 1500 Solid

85 1-2-ethylaminopropane 2000 Liquid

86 Methylisobutyl ketone 1000 Liquid

87 potassium carbonate 1000 Solid

Total RM quantity 274000 274 MT

Annexures GCPL 72

Proposed List of Raw Material – Solvents

Sl. No. Total qty of solvent Lts/ annum Storage

1 Toluene 45000 U/G

2 DMF 6000 Barrel

3 Acetone 46000 U/G

4 Hexane 12000 Barrel

5 DNS 300000 U/G

6 Methanol 800000 U/G

7 THF 12000 Barrel

8 Pyridine 8000 Barrel

9 MTBE 16000 Barrel

10 EDC 31000 U/G

11 MDC 34000 Barrel

12 Isopropanol 16000 Barrel

13 Ethyl Acetate 21000 U/G

Total 1347000

Annexures GCPL 73

ANNEXURE – VII EMISSION CHARACTERISTICS

Annexures GCPL 74

Stack Emission Characteristics (Existing) Stack No 1 2 3 4 5 6 7 8 9 10-12 13

Material of Construction S.S S.S M.S M.S M.S FRP M.S M.S FRP G.I M.S

Stack attached to Spray Drier – 1

Spray Drier - 2

3 T BOILER

D.G.Set 380 KVA

D.G.Set 180 KVA

ATFD Reactor

AHU Drier AHU Blender

AHU Exhaust

Fluid Bed Drier 120

kgs (3 Nos)

Fluid Bed Drier 120

kgs

Stack height Above the ground level in m 22.0 22.0 30.0 10.0 10.0 12.0 12.0 10.0 10.0 2.92 each 7.0

Stack top Circular/Rectangular /Square

Circular Circular Circular Circular Circular Circular Circular Rectangular Circular Rectangular Circular

Inside dimensions of the stack at top, mm 400 400 600 125 125 400 400 400 x 200 400 300 x 200 each

300

Gas quantity – m3/hr 15000 15000 19000 3200 1900 3600 3600 3600 4000 4000 2800

Flue gas temperature, oC 110 110 84 300 250 78 78 78 190 140 100

Exit velocity of the gas, m/s 20.0 20.0 22.0 12.6 16.8 10.0 10.0 10.0 9.0 9.0 6.0

Emission concentration , mg/m3

SO2 - - 13.0 55.5 50.13 - - - - 300 200

NOx - - 12.0 44.0 0.56 - - - - 95 63

SPM - - 106.0 5.0 14.5 75.0 75.0 75.0 50 140 100

Br - - - - - - - - - - -

Emission rate, g/s

SO2 - - 0.0025 0.062 0.021 - - - - 0.333 0.222

NOx - - 0.0023 0.048 0.00008 - - - - 0.105 0.070

SPM - - 0.02 0.0056 0.09 0.075 0.075 0.075 0.05 0.167 0.111

Br - - - - - - - - - - -

Annexures GCPL 75

Stack Emission Characteristics (Proposed) Stack No 1 2 3 4

Material of Construction M.S FRP FRP M.S

Stack attached to 3 T BOILER

Reactor Reactor D.G.Set 250 KVA

Stack height Above the ground level in m 30.0 12.0 12.0 10.0

Stack top Circular/Rectangular /Square

Circular Circular Circular Circular

Inside dimensions of the stack at top, mm 600 400 400 125

Gas quantity – m3/hr 16000 20000 20000 2600

Flue gas temperature, oC 140 35 35 250

Exit velocity of the gas, m/s 16.0 28.0 28.0 15.0

Emission concentration , mg/m3

SO2 - - - 52.13

NOx - - - 0.58

SPM - - - 15.5

Br - - - -

Emission rate, g/s

SO2 - - - 0.052

NOx - - - 0.032

SPM - - - 0.009

Br - - - -

Annexures GCPL 76

ANNEXURE – VIII FUGITIVE EMISSION

Annexures GCPL 77

FUGITIVE EMISSION CONTROL MEASURES

Equipment Control Measures Monitoring

Reactors Each reactor is

connected to 2-

consecutive

condensers for

recovery of solvent

residue.

The Reactors after

condenser are

connected to a

Scrubber of 4000

m³/hr capacity.

Solvent will be

absorbed in water

and water +

Solvent mixture

shall be taken to

stripper to

separate the

solvent and water.

VOC Online

Monitoring will be

installed near

Reactors at Shop

Floor.

Solvent

Storage Area

All Underground

tanks vent shall be

connected through

25NB pipeline to 1m²

condenser with

chilled water coolant

15°C, condensed

solvent shall be

collected in a

receiver. Mixed

solvent shall be

taken for process

based on suitability.

Note: Stored

solvents are non-

volatile which are

having high Boiling

point (>65°C) and

vapour pressure is

also very less.

VOC Online

Monitoring will be

installed at the

Solvent Storage

area.

Annexures GCPL 78

ANNEXURE – IX RISK IDENTIFICATION

Annexures GCPL 79

Identification of Vulnerable Areas in the Plant, and Selection of Worst Case

Scenarios

Production of API Products will involve batch process, and amount of chemicals

involved in each batch Operation is not identical. The very process itself, solvents will

not produce any excessive pressure and or temperature. As such the possibility of any

major accidents in the process per se which produce emergency situation is not

expected. Even in Reactor, which is an exothermic reaction, the temperature rise can

occur only due to cooling water failure/inadequacy or addition of excessive Solvents.

This condition can be controlled by reducing the rate of addition of solvents or

increasing the cooling water flow. Taking also into consideration the simplicity of the

process, no serious accident of that proportion that can create emergency condition is

expected. It is possible that emergency condition can be produced in the factory due to

failure of any one of the storage tank. In this case the entire quantity of solvents stored

may get released from the tank. Hence release of solvent from the storage tank has

been taken as the worst case scenario and the effect of released it to the surrounding

has been assessed using TNO’s. Effect software for dispersion.

Risk Register

Sl.

No Risk Description

What is Risk?

(Potential failure

mode)

Impact / effect of Risk (Risk

leads to)

1. Unloading Solvents Spillage of solvents,

Fire

a. Personnel safety

b. Solvent vapour inhalation

c. Ignition on static electricity

i. Leakage from the flange/ hose

joints.

ii. Accidental spillages

Overflow from the tank

2 Underground

storage tank Fire, leakages

i. Exposure of direct sunlight

ii. Solvent is transferred to tank at

high rate

iii. Leakages from tank

3

Supply from

Service tank to

Production

Leakage, line blockage

i. Heavy leakage/Line blockage/

Fracture in the pipe line.

ii. Equipment failure, flange leak

4

Personnel

Qualification &

Responsibilities

Inadequate no of

personnel, education &

training

Responsibilities not

defined or not

documented

i. Impact on the quality of product.

ii. Affects personnel safety

Annexures GCPL 80

ANNEXURE – X TOPO MAP

Annexures GCPL 81

Annexures GCPL 82

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