CFE AGENDA ITEM No. Dt: 18.07.2019

OCMMS application 01) Name of the Industry &

Location address with Sy. Nos.

: M/s. Porus Laboratories Pvt. Ltd., Unit – IV, Sy. No. 106, 107/1&2, 108/1&2, Akkireddygudem (V), Musunuru (M), Krishna District. Applied for CFE for Change of Product Mix

02) EC status : EC order dt. 02.01.2019 issued by MoEF&CC, GoI for expansion of Active Pharmaceutical Ingredients and its intermediates manufacturing unit.

03) Project cost :

No additional investment

04) Project site details: : i) Total area of the land : 102251.41 m2 (25.25 acres) (existing land area

64818 m2+ 37433.41 m2)

ii) Built up area : 50172.51 sq.mtrs (12.39 acres which includes roads & ETP area)

iii) Greenery : Industry proposed to develop 47248.64 sq.mtrs (11.27acres)

iv) Nearest Human habitation : Akkireddygudem (V) at a distance of 0.5 km.

v) Nearby water body : Vempadu major canal is existing at a distance of 0.23 km in W direction; Pont near Akkireddigudem is at a distance of 0.4 km in E direction’ Pond near Ramanakkapeta is a distance of 1.15 km in W direction; Ramlinga Cheruvu is at a distance of 4 km in SE direction; Pedda cheruvu is at a distance of 3.3 km in E direction.

vi) Surroundings of the site :

North : Agricultural lands South : Agricultural lands East : R&B road is existing West : Agricultural lands vii) Road details :

5) Products & By Products: Bulk drug and drug intermedies along with R&D facility.

As per CFE expansion order dt. 31.12.2018:

S.No. Name of the products Qty. after expansion in (kg/day)

Phase – I including existing

After Phase – II

After Phase - III

1 Bisphenol Acetophenone -- 333.33 333.33

2 P-Phenolphthalein bisphenol (or) 2-Phenyl-3,3-Bis (4-Hydroxy Phenyl) Phthalimide (PPPBP)

6666.67 10000.0 10000.0

3 1,5-Bis-[2,6-dimethyl-4-(2-methyl-2-propenoxy) phenyl}-penta-(2,6-dimethyl-1,4-phenyleneoxide (MX-9000)

1389.0 1389.0 1389.0

4 Tetramethyl bisphenol acetone (TMBPA)

276.67 276.67 276.7

5 [1,1,1-Tri-(4-hydroxy phenyl)] ethane (THPE)

-- 276.67 276.7

6 4-Hydroxybenzonitrile (HBN) -- 276.67 276.7

7 4-Nitro-N-methyl phthalimide (4-NP)

13889.0 13889.0 13889.0

8 3-(2-(Dimethyl amine) ethyl ) –N-methyl-1H-indole-5-methane sulfonamide

-- 366.67 366.67

9 Sumatriptan Succinate 16.7 16.7 16.7

10 Ciprofloxacin Hydrochloride -- -- 1666.7

11 Metformin Hydrochloride -- -- 666.7

12 Venlafaxine Hydrochloride -- -- 33.3

13 Sertraline Hydrochloride -- -- 166.7

14 Celecoxib -- -- 100.0

15 Clopidogrel Hydrogen Bisulfate

-- -- 1000.0

16 Enrofloxacin -- -- 33.3

17 Pioglitazone Hydrochloride -- -- 66.67

18 Gabapentin -- -- 1666.7

19 R&D Activity 0.55 0.55 0.55

Total 22238.59 26825.23 32225.24

20 Power Plant - - 3 MW

Total production capacity 18 products at a time (32225.24 kg/day) and R&D facility with 3MW Captive Power plant.

List of By-Products:

S.No. Name of the products Qty. after expansion in (kg/day)

Phase – I including existing

After Phase – II

After Phase - III

1 Piperazine ML’s -- -- 9756.7

2 N-Ethyl Piperazine ML’s -- -- 202.2

3 Spent Sulfuric Acid 245126 245126 245126

or or or or

Gypsum 75000 75000 75000

The industry obtained CFO for phase –I vide order dt.08-05-2019. Thus, the industry

commissioned Phase – I only.

Now, the industry proposed for Change of Product Mix with no increase in pollution load and production capacity by enhancing the production capacity of one permitted product i.e., 1,5-Bis-[2,6-dimethyl-4-(2-methyl-2-propenoxy) phenyl}-penta-(2,6-dimethyl-1,4-phenyleneoxide (MX-9000) from 1389Kgs/day to 4000Kgs/day by reducing the production capacity of another permitted product i.e., P-Phenolphthalein bisphenol (or) 2-Phenyl-3,3-Bis (4-Hydroxy Phenyl) Phthalimide (PPPBP) from 6666.67 Kgs/day to 4055.67Kgs/day.

After Change of Product Mix:

Sl.No. Name of the products Permitted

Quantity in kg/day

Proposed quantity in

Kgs/day Status

1 P-Phenolphthalein bisphenol (or) 2-Phenyl-3,3-Bis (4-Hydroxy Phenyl) Phthalimide (PPPBP)

6666.67 4055.67 Reduced

2 1,5-Bis-[2,6-dimethyl-4-(2-methyl-2-propenoxy) phenyl}-penta-(2,6-dimethyl-1,4-phenyleneoxide (MX-9000)

1389.0 4000 Increased

3 Tetramethyl bisphenol acetone (TMBPA)

276.67 276.67 Retained

4 4-Nitro-N-methyl phthalimide (4-NP)

13889.0 13889.0 Retained

5 Sumatriptan Succinate 16.7 16.7 Retained

6 R&D Activity 0.55 0.55 Retained

Total 22238.59 22238.59

List of By-Products:

S.No. Name of the products Quantity in kg/day

1 Spent Sulfuric Acid 245126

06) Water consumption: Source of Water supply : Bore well within the industry premises

As per CFE expansion order dt. 31.12.2018:

S.No. Purpose

Quantity (KLD)

Phase – I including existing

After Phase – II

After Phase - III

1 Process 397 527 579

2 Scrubber 5 10 20

3 Q.C. and R&D 1 3 5

4 Washings 5 10 20

5 Boiler 67 151 332

6 Cooling makeup 120 250 540

7 DM Plant 5 10 16

8 Domestic 10 12 15

9 Green belt 10 25 60

Total 620 998 1587

The industry proposed to recycle 829 KLD of treated waste water hence fresh water requirement is 758 KLD

After Change of Product Mix:

As per the CFO order dt.08-05-2019, the permitted total water consumption for existing products is 620KLD. Out of which the water consumption for process is 397KLD. Due to the proposed Change of Product Mix, the water requirement for process is reduced from 397KLD to 323.4 KLD and the total water consumption for change of product mix is reduced from 620KLD to 546.4KLD for the same quantity of production of 22238.59 kgs/day as permitted in the CFO order dt.08.05.2019.

07) Waste Water Generation:

As per CFE expansion order dt. 31.12.2018:

S. No.

Purpose

Qty. after expansion (KLD)

Phase – I including existing

After Phase – II

After Phase - III

1 Process 415.7 557.2 648

2 DM Plant 5 10 16

3 Scrubber 5 10 20

4 Q.C. and R&D 1 3 5

5 Washings 5 10 20

S.No. Purpose Quantity (KLD)

Existing Proposed

1 Process 397 323.4

2 Scrubber 5 5

3 Q.C. and R&D 1 1

4 Washings 5 5

5 Boiler 67 67

6 Cooling makeup 120 120

7 DM Plant 5 5

8 Domestic 10 10

9 Green belt 10 10

Total 620 546.4

6 Boiler blow down 7 14 32

7 Cooling bleed of 12 25 45

8 MEE steam condensate 35 70 140

9 Domestic 8 9.6 12

Total 493.7 708.8 938

The industry shall recycle 829 KLD of treated waste water. After Change of Product Mix:

As per the CFO order dt.08-05-2019, the permitted total waste water generation for existing products is 493.7KLD. Out of which process waste water generation for process is 415.7KLD. Due to the proposed Change of Product Mix, the waste water generation for process is reduced from 415.7KLD to 336.2KLD and the total waste water generation for change of product mix is reduced from 493.7 KLD to 414.2KLD for the same quantity of production of 22238.59 kgs/day as permitted in the CFO order dt.08.05.2019.

ETP Details & Mode of Disposal:

Existing ETP:

As per CFO order dt.08-05-2019, the waste water generation, treatment and disposal details are as follows:

Outlet No.

Outlet Description Max Daily Discharge

Point of Disposal

1. Process-415.7KLD +DM plant -5KLD+Scrubber-5KLD Q.C. and R&D-1KLD,washing-5KLD +Boiler blow down-7KLD+Cooling bleed of-12KLD +MEE steam condensate

485.7KLD The HTDS waste water treatment facility consisting of stripper (15KL/hr), MEE(15KL/hr), ATFD(3KL/hr) and the LTDS waste water treatment facility consisting of Collection cum equalization cum neutralization , Aeration, Pressure sand filter, Activated carbon filter followed by 13KL/hr RO. After treatment,

RO permeate to cooling tower for boiler makeup.

RO rejects to MEE

MEE & ATFD condensate to biological ETP

MEE contrite to ATFD.

ATFD salts to TSDF

Stripped solvents to APPCB authorized cement industries /solvent recovery units

2. Domestic 8.0 KLD After treatment in Biological ETP (12KLD) consisting of collection tank Aeration tank.

S. No.

Purpose Quantity

(KLD) Mode of final disposal

1 Process 336.2 i. HTDS effluents after neutralization send to Stripper, MEE and ATFD.

ii. The condensate from MEE &ATFD sent to ETP.

iii. LTDS effluents after neutralization sent to ETP followed by RO plant.

iv. RO permeate is proposed to reuse for boiler feed & RO rejects will be routed through MEE.

2 Scrubber 5

3 Q.C. and R&D 1

4 Washings 5

5 Boiler blow down 7

6 Cooling bleed off 12

7 DM Plant 5

8 MEE steam condensate

35

9 Domestic 8

Total 414.2

Proposed ETP:

Phase-I including existing

After Phase-II After Phase-III After Phase-III Mode of final disposal

ETP capacity 300KLD consisting of Stripper(15KL/hr), MEE(15KL/hr),ATFD(3KL/hr) RO(13KL/hr)

ETP capacity 500KLD consisting of Stripper(25KL/hr),MEE(25KL/hr), ATFD(5KL/hr) RO(22KL/hr)

ETP capacity 750KLD consisting of Stripper(50KL/hr),MEE(50KL/hr),ATFD(12KL/hr) RO(50KL/hr)

i) MEE & ATFD condensate to Biological ETP

ii) MEE concentrate to ATFD

iii) ATFD salts to TSDF iv) Stripped solvents to

APPCB authorised cement industries/Solvent recovery units

Source of effluent Treatment Mode of final disposal

Washing, boiler blow down, cooling tower blow down, QC& R&D

300KLD consists of collection –Equalization-Neutralization-ETP(Biological treatment) along with –MEE condensate, Domestic waste water- Pressure sand filter-Activated filter-RO

RO permeate to cooling tower and boilers RO rejects to MEE

Domestic waste water 12KLD consists of Collection tank-Aeration tank(Biological ETP)

08) Hazardous / Solid Waste details: (As per CFE order dt. 31.12.2018)

S No.

Name of the Waste Phase-I

including existing

After Phase-II

After Phase-III

Disposal option

1 Organic residue 4.6TPD 7.75TPD 11.2TPD TSDF, Parawada, for incineration / Authorized Cement plants for cc-processing.

2 Spent carbon 2.16TPD 3.62TPD 3.7TPD

3 Distillation bottom Residue (1% of spent solvents)

0.6TPD 1.0TPD 1.8TPD

4 Inorganic & Evaporation salts(process)

44TPD 53.3TPD 62.4TPD TSDF, Parawada for secured land fill.

5 Evaporation salts (Non-process)

1TPD 2TPD 3.5TPD

6 ETP sludge 2.5TPD 5TPD 10TPD

7 Used oil / Waste lubricant oil/Grease

1KL /Annum

2KL /Annum

3KL /Annum

Authorized preprocessors / recyclers.

8 Detoxified Containers & Container Liners a) HDPE Drums b) Plastic Bags c) Carbouys

250Nos /Annum

500Nos /Annum

1000Nos /Annum

After complete detoxification, it shall be disposed to outside agencies.

9 Spent solvents 60KLD 100KLD 185KLD Shall be recovered within the premises/ to authorised agency for recovery.

10 Recovered Solvents from spent solvents

54KLD 90KLD 165KLD Reused

11 Spent Mixed solvents 5KLD 10KLD 17KLD To authorized recovery units/Authorized cement plant for co-processing

12 Used Lead acid batteries

25Nos /Annum

50Nos /Annum

100Nos /Annum

To dealers on buy back basis

13 Misc. Waste (spill control waste)

6TPA 12TPA 24TPA To TSDF, Parawada for further treatment and disposal.

14 Spent Catalyst 2TPA 4TPA 8.4TPA Sent for re-generation

15 Used insulation waste ,PVC scrap, HDPE&PP scrap, Paper waste, used thermocouple waste, Glass scrap, Iron scrap, SS scrap, Aluminium & other metal scrap, cotton waste (used aprons/uniformsetc.,)Packing wood etc.,

0.25TPD 0.5TPD 1TPD To TSDF, Parawada, for incineration / Authorized Cement plants for co-processing/authorized agencies

16 Kitchen waste from canteen

0.1TPD 0.15TPD 0.2TPD To Municipal dump yard/Composting

17 Boiler Ash 12TPD 29TPD 42TPD To brick manufacturer

Bio-medical waste:

Biomedical waste and E- Waste Generation, Handling and disposal from occupational Health centre (OHC):

S. No.

Name of the Waste

Phase – I Including existing kg/day

After Phase – II

kg/day

After Phase – III

kg/day

Disposal Option

1 Category: Yellow Decontaminated media from Microbiology lab

-- 10 20 Pre-treat to sterilize with non-chlorinated chemicals on-site as per BMW Rules and sent to Common Biomedical Waste Treatment Facility (CBMWTF) for incineration.

2 Category: White Waste sharps from OHC (Needles, Syringes, Scalpels, Blades, Glass etc.,)

0.02 0.05 0.1 Autoclaving and sent to CBMWTF

3 Category: Yellow Soiled waste from OHC( Cotton, dressings, soiled plaster casts other material)

0.1 0.2 0.3 Shall sent to Common Biomedical Waste Treatment Facility (CBMWTF) for incineration.

4 E-waste 3 5 10 Sent to authorized E-waste collection centers/registered dismantlers/authorized recyclers/ return back to manufacturer.

After Change of Product Mix:

S No.

Name of the Waste Proposed

HW quantity Mode of final disposal

1 Organic residue 4.5TPD TSDF, Parawada, for incineration / Authorized Cement plants for cc-processing.

2 Spent carbon 1.32 TPD

3 Distillation bottom Residue (1% of spent solvents)

0.6TPD

4 Inorganic & Evaporation salts(process)

40.5TPD TSDF, Parawada for secured land fill. 5 Evaporation salts (Non-process) 1TPD

6 ETP sludge 2.5TPD

7 Used oil / Waste lubricant 1KL Authorized preprocessors /

oil/Grease /Annum recyclers.

8 Detoxified Containers & Container Liners d) HDPE Drums e) Plastic Bags f) Carbouys

250Nos /Annum 50kgs/month

After complete detoxification, it shall be disposed to outside agencies.

9 Spent solvents 60KLD Shall be recovered within the premises/ to authorised agency for recovery.

10 Recovered Solvents from spent solvents

54KLD Reused

11 Spent Mixed solvents 5KLD To authorized recovery units/Authorized cement plant for co-processing

12 Used Lead acid batteries 25Nos /Annum

To dealers on buy back basis

13 Misc. Waste (spill control waste) 6TPD To TSDF, Parawada for further treatment and disposal.

14 Spent Catalyst 2TPA Sent for re-generation

15 Used insulation waste ,PVC scrap, HDPE&PP scrap, Paper waste, used thermocouple waste, Glass scrap, Iron scrap, SS scrap, Aluminium & other metal scrap, cotton waste (used aprons/uniformsetc.,)Packing wood etc.,

0.25TPD To TSDF, Parawada, for incineration / Authorized Cement plants for co-processing/authorized agencies

16 Kitchen waste from canteen 0.1TPD To Municipal dump yard/Composting

17 Boiler Ash 12TPD To brick manufacturer

Biomedical waste and E- Waste Generation, Handling and disposal from occupational Health centre (OHC): Not submitted the details.

09) Air pollution:

S. No.

Source of Pollution

Control equipment provided Stack

ht.

1. 30 TPH Boiler ESP 55 m

2. 10 TPH Coal / Husk / Pellets fired boilers

Multi Cyclone Separator & Bag-filter 40 m

3 8 TPH Boiler will be standby Multi Cyclone Separator & Bag-filter 30 m

4 1 lakh K.cal/hr diesel fired Thermic Fluid Heater(TFH)

Cyclone separator & Bag-filter 30 m

5 1 x 320 KVA D.G. Set Acoustic enclosure 8 m

6 1 x 380 KVA D.G. Set Acoustic enclosure 8 m

7 2 x 1000 KVA DG Set Acoustic enclosure 11 m

8 3 x 500 KVA DG Set Acoustic enclosure 9 m

a) As per CFO order dt.08-05-2019, the permitted sources of air pollution and air pollution

control equipment details for phase –I are as follows:

S. No.

Source of Pollution

Control equipment provided

Stack ht.

1. 8 TPH Coal/Husk/Pellets fired Boiler.

Multi Cyclone Separator & Bag-filter

30 m

2. Process emissions Scrubber with water/caustic solution

-

3 500 KVA DG Set Acoustic enclosure 9m

4 500 KVA DG Set Acoustic enclosure 9m

5 1 x 380 KVA D.G. Set Acoustic enclosure 8 m

6. 1 x 320 KVA D.G. Set Acoustic enclosure 8 m

b) For the propose product mix, the existing boiler and DG sets will be utilized. No additional

boiler proposed.

10) Compliance status of conditions stipulated in Schedule B of conditions of CFO order

Dt.08-05-2019 is as follows:

S. No.

Condition Compliance

5 The industry shall provide digital flow meters with totalizer facility at the outlet of ATFD, RO permeate and RO reject and maintain records.

Not complied. Industry has provided flow meters with totalizer facility at Stripper feed, inlet of ATFD, LTDS, HTDS, RO feed and RO permeate and maintaining the records. Stripper feed– 43940 KL, ATFD –not showing the value. The LTDS –5133KL (inlet to ETP), HTDS –5981KL, RO feed-35.1KL and RO permeate-973KL The industry has to provide flow meter with totalizer facility at outlet of stripper, inlet of MEE, MEE condensate and MEE concentrate, inlet of ATFD and RO reject.

6 The industry shall suitably change the digital flow meter location to RO Permeate tank and also change the location of the web camera to RO permeate tank for real time monitoring of recycling of RO permeate in consultation with RO: Vijayawada

Not Complied

The industry has provided flow meter with totaliser facility at RO permeate pipeline before going to RO permeate storage tank and also provided web camera focussing digital flow meters of LTDS,HTDS and RO permeate . But, The industry shall suitably change the digital flow meter location to RO Permeate tank and also change the location of the web camera / shall provide web camera at RO permeate tank for real time monitoring of recycling of RO permeate.

23 The industry shall operate online monitoring systems and connect monitoring system to APPCB/CPCB websites as per CPCB directions dated 05.02.2014. The online monitoring system shall be calibrated periodically as per equipment suppliers manual / CPCB guidelines

Partially Complied

The industry has provided flow meter with totaliser facility at RO permeate pipeline before going to RO permeate storage tank and also provided web camera focussing digital flow meters of LTDS,HTDS and RO permeate . But, The industry shall suitably change the digital flow meter location to RO Permeate tank and also change the location of the web camera at RO permeate tank for real time monitoring of recycling of RO permeate.

29 The industry shall install online monitoring systems and connect monitoring system to APPCB/CPCB websites as per CPCB directions dated 05.02.2014 & 02.03.2015 and guidelines issued regarding online monitoring systems from time to time

Partially Complied

The industry has provided flow meter with totaliser facility at RO permeate pipeline before going to RO permeate storage tank and also provided web camera focussing digital flow meters of LTDS,HTDS and RO permeate . But, The industry shall suitably change the digital flow meter location to RO Permeate tank and also change the location of the web camera at RO permeate tank for real time monitoring of recycling of RO permeate.

33 The industry shall comply with the Standard Operating Procedure (SOP) and Checklist of Minimal Requisite Facilities for Utilization of Spent Solvent for Recovery of Solvent specified for Solvent Recovery Units issued by CPCB

Partially complied

The industry was instructed to comply with the Standard Operating Procedure (SOP) and Checklist of Minimal Requisite Facilities for Utilization of Spent Solvent for Recovery of Solvent specified for Solvent Recovery Units issued by CPCB

Not provided TOC analyser

36 Stringent action will be taken against the industries who are giving the spent solvent to recycling industries without following the manifest system

The industry was instructed to comply.

38 The industry shall submit compliance report on the conditions mentioned in the consent order every six months i.e., on 1st of January and July of every year to the RO /ZO

The industry was instructed to comply.

11) Recommendations of the Regional Officer: 1. The existing industry obtained environmental clearance for expansion of Active

Pharmaceutical Ingredients & its intermediates manufacturing vide order F.No.J-11011/265/2015-IAII (I), MoEF&CC, GOI, New Delhi, Dt. 02.01.2019. The permitted products and by products are as follows:

S.No. Name of the products Qty. after expansion in (kg/day)

Existing Proposed Total

1 Bisphenol Acetophenone -- 120 120

2 P-Phenolphthalein bisphenol (or) 2-Phenyl-3,3-Bis (4-Hydroxy Phenyl) Phthalimide (PPPBP)

3600 3600

3 1,5-Bis-[2,6-dimethyl-4-(2-methyl-2-propenoxy) phenyl}-penta-(2,6-dimethyl-1,4-phenyleneoxide (MX-9000)

-- 500 500

4 Tetramethyl bisphenol acetone (TMBPA)

-- 99.6 99.6

5 [1,1,1-Tri-(4-hydroxy phenyl)] ethane (THPE)

-- 99.6 99.6

6 4-Hydroxybenzonitrile (HBN) -- 99.6 99.6

7 4-Nitro-N-methyl phthalimide (4-NP)

-- 5000 5000

8 3-(2-(Dimethyl amine) ethyl ) –N-methyl-1H-indole-5-methane sulfonamide

-- 132 132

9 Sumatriptan Succinate 6 -- 6

10 Ciprofloxacin Hydrochloride 600 -- 600

11 Metformin Hydrochloride 600 (-360) 240

12 Venlafaxine Hydrochloride 12 -- 12

13 Sertraline Hydrochloride 24 60 60

14 Celecoxib 60 (-24) 36

15 Clopidogrel Hydrogen Bisulfate 60 300 360

16 Enrofloxacin 360 (-348) 12

17 Gabapentin 24 (-576) -600

18 Ibuprofen Paracetamol 1200 0 0

19 Pioglitazone Hydrochloride 1200 0 0

Total

3000 (any 3 products)

-- 11600.8

20 R&D Activity -- 0.2 0.2

Total production capacity (18 products at a time and R&D) with 3MW Captive Power plant.

11,601 (at all products)

b) By-Product

S.No. By-Products Quantity (TPA)

Existing Proposed Total

1 Piperazine ML’s 3512.4 0 3512.4

2 N-Ethyl Piperazine ML’s 2183.4 (-2110.6) 72.8

3 Spent Sulfuric Acid -- 88243 88243

4 Hydrochloric Acid (25%) 3960 0 0

5 Aluminium Hydroxide Gel 5255.5 0 0

6 Cromic Sulphate Solution 2501.7 0 0

2. The industry obtained CFE for expansion for the following products vide order

dated.31.12.2018 and proposed to produce the following products in Phase-I, Phase-II and Phase-III with a total production of 18 products at a time - 32225.24 kg/day along with R&D Activity - 0.55 kgs/day:

S.No. Name of the products Qty. after expansion in (kg/day)

Phase – I including existing

After Phase – II

After Phase - III

1 Bisphenol Acetophenone -- 333.33 333.33

2 P-Phenolphthalein bisphenol (or) 2-Phenyl-3,3-Bis (4-Hydroxy Phenyl) Phthalimide (PPPBP)

6666.67 10000.0 10000.0

3 1,5-Bis-[2,6-dimethyl-4-(2-methyl-2-propenoxy) phenyl}-penta-(2,6-dimethyl-1,4-phenyleneoxide (MX-9000)

1389.0 1389.0 1389.0

4 Tetramethyl bisphenol acetone (TMBPA)

276.67 276.67 276.7

5 [1,1,1-Tri-(4-hydroxy phenyl)] ethane (THPE)

-- 276.67 276.7

6 4-Hydroxybenzonitrile (HBN) -- 276.67 276.7

7 4-Nitro-N-methyl phthalimide (4-NP)

13889.0 13889.0 13889.0

8 3-(2-(Dimethyl amine) ethyl ) –N-methyl-1H-indole-5-methane sulfonamide

-- 366.67 366.67

9 Sumatriptan Succinate 16.7 16.7 16.7

10 Ciprofloxacin Hydrochloride -- -- 1666.7

11 Metformin Hydrochloride -- -- 666.7

12 Venlafaxine Hydrochloride -- -- 33.3

13 Sertraline Hydrochloride -- -- 166.7

14 Celecoxib -- -- 100.0

15 Clopidogrel Hydrogen Bisulfate

-- -- 1000.0

16 Enrofloxacin -- -- 33.3

17 Pioglitazone Hydrochloride -- -- 66.67

18 Gabapentin -- -- 1666.7

19 R&D Activity 0.55 0.55 0.55

Total 22238.59 26825.23 32225.24

20 Power Plant - - 3 MW

Total production capacity (18 products at a time (32225.24 kg/day) and R&D with 3MW Captive Power plant

11,601 (at all products)

3. The industry obtained consent & authorization order on 08-05-2019 which is valid upto 31-03-2024 for Phase-I for the following products:

Sl.No. Name of the products Quantity in kg/day

1 P-Phenolphthalein bisphenol (or) 2-Phenyl-3,3-Bis (4-Hydroxy Phenyl) Phthalimide (PPPBP)

6666.67

2 1,5-Bis-[2,6-dimethyl-4-(2-methyl-2-propenoxy) phenyl}-penta-(2,6-dimethyl-1,4-phenyleneoxide (MX-9000)

1389.0

3 Tetramethyl bisphenol acetone (TMBPA) 276.67

4 4-Nitro-N-methyl phthalimide (4-NP) 13889.0

5 Sumatriptan Succinate 16.7

6 R&D Activity 0.55

Total 22238.59

4. Now, the industry proposed for Change of Product Mix with no increase in pollution load and production capacity by enhancing the production capacity of one permitted product i.e., 1,5-Bis-[2,6-dimethyl-4-(2-methyl-2-propenoxy) phenyl}-penta-(2,6-dimethyl-1,4-phenyleneoxide (MX-9000) from 1389Kgs/day to 4000Kgs/day by reducing the production capacity of another permitted product i.e., P-Phenolphthalein bisphenol (or) 2-Phenyl-3,3-Bis (4-Hydroxy Phenyl) Phthalimide (PPPBP) from 6666.67 Kgs/day to 4055.67Kgs/day. The Change of Product Mix details are as follows:

Sl.No. Name of the products Permitted

Quantity in kg/day

Proposed quantity in

Kgs/day Status

1 P-Phenolphthalein bisphenol (or) 2-Phenyl-3,3-Bis (4-Hydroxy Phenyl) Phthalimide (PPPBP)

6666.67 4055.67 Reduced

2 1,5-Bis-[2,6-dimethyl-4-(2-methyl-2-propenoxy) phenyl}-penta-(2,6-dimethyl-1,4-phenyleneoxide (MX-9000)

1389.0 4000 Increased

3 Tetramethyl bisphenol acetone (TMBPA)

276.67 276.67 Retained

4 4-Nitro-N-methyl phthalimide (4-NP)

13889.0 13889.0 Retained

5 Sumatriptan Succinate 16.7 16.7 Retained

6 R&D Activity 0.55 0.55 Retained

Total 22238.59 22238.59

5. The industry obtained CFO vide order dt.08-05-2019 for phase –I products and the water consumption details for phase –I is as follows:

6. The water consumption quantities for the proposed Change of Product Mix is as follows:

As per the

CFO order dt.08-05-2019, the permitted total water consumption for existing products is 620KLD. Out of which the water consumption for process is 397KLD. Due to the proposed Change of Product Mix, the water requirement for process is reduced from 397KLD to 323.4 KLD and the total water consumption for change of product mix is reduced from 620KLD to 546.4KLD for the same quantity of production of 22238.59 kgs/day as permitted in the CFO order dt.08.05.2019.

7. The permitted waste water generation quantities as per the CFO order dt.08-05-2019 for phase –I products is as follows:

S.No. Purpose Qty. after expansion in (KLD) as per CFE order dt.31.12.2018 for Phase – I including existing

1 Process 415.7

2 DM Plant 5

3 Scrubber 5

4 Q.C. and R&D 1

5 Washings 5

6 Boiler blow down 7

7 Cooling bleed of 12

S.No. Purpose Quantity in KLD

1 Process 397

2 Scrubber 5

3 Q.C. and R&D 1

4 Washings 5

5 Boiler 67

6 Cooling makeup 120

7 DM Plant 5

8 Domestic 10

9 Green belt 10

Total 620

S.No. Purpose Quantity in KLD

Existing Proposed

1 Process 397 323.4

2 Scrubber 5 5

3 Q.C. and R&D 1 1

4 Washings 5 5

5 Boiler 67 67

6 Cooling makeup 120 120

7 DM Plant 5 5

8 Domestic 10 10

9 Green belt 10 10

Total 620 546.4

8 MEE steam condensate 35

9 Domestic 8.0

Total 493.7

8. The waste water generation quantities for the proposed Change of Product Mix treatment and disposal is as follows:

As per the CFO order dt.08-05-2019, the permitted total waste water generation for existing products is 493.7KLD. Out of which process waste water generation for process is 415.7KLD. Due to the proposed Change of Product Mix, the waste water generation for process is reduced from 415.7KLD to 336.2KLD and the total waste water generation for change of product mix is reduced from 493.7 KLD to 414.2KLD for the same quantity of production of 22238.59 kgs/day as permitted in the CFO order dt.08.05.2019.

9. The existing industry is having ZLD system. ZLD system consisting of Biological ETP (300 KLD), RO plant (13 KL/hr) and stripper, MEE and ATFD. The Biological ETP consisting of collection cum equalization cum neutralization, Aeration, pressure sand filter, activated carbon filter followed by 13KL/hr RO plant. RO rejects is treated in Stripper, MEE followed by ATFD. RO permeate is utilizing as a boiler feed. MEE & ATFD condensate is routed through Biological ETP. ATFD salt is disposed to TSDF Parwada for scientific disposal. For the proposed change of product mix, waste water generation is reduced from 493.7 KLD to 414.2 KLD. Hence the proposed change of product mix may be considered as no increase in pollution load and production capacity.

10. The existing industry production details for the period from Jan, 2019 to June, 2019 is as follows:-

S.No. Name of the product Jan, 2019

Feb, 2019

March, 2019

April, 2019

May, 2019

June, 2019

1 P-Phenolphlthalin bisphenol

0 0 58.91 0 0 64.832

2 N-Nitro-N-Methyl Bisphenol acetone (TMBPA)

99.6 95.3 99.6 96.6 239.4 291.042

3 MX-9000 15.6 14.2 15.7 15.2 32.1 41.1

As per the production details submitted by the industry, the industry produced P- Phenolphlthalin bisphenol, MX-9000 and 4-Nitro-N-Methyl Phthalimide (4-NP) and the production details are within the permitted capacities.

11. As per the information submitted by the industry, water consumption details for the period from Jan, 2019 to June, 2019 are as follows:

S.No. Water consumption Jan, 2019

Feb, 2019

March, 2019

April, 2019

May, 2019

June, 2019

1 Process 729 678 780 557 4013 5386

2 Boiler feed 1022 967 1093 1104 1377 1410

3 Domestic 171 158 158 183 199 230

Total 1922 1803 2031 1844 5588 7026

Water consumption details are within the permitted quantities.

12. As per the information submitted by the industry, the waste water generation quantities for the period from Jan, 2019 to June, 2019 are as follows:

S.No. Purpose Quantity in KLD Disposal

Existing Proposed

1 Process 415.7 336.2 i) HTDS effluents after neutralization send to Stripper, MEE and ATFD.

ii) The condensate from MEE &ATFD sent to ETP.

iii) LTDS effluents after neutralization sent to ETP followed by RO plant.

iv) RO permeate is proposed to reuse for boiler feed & rejects sent back to MEE

2 Scrubber 5 5

3 Q.C. and R&D 1 1

4 Washings 5 5

5 Boiler blow down

7 7

6 Cooling bleed off

12 12

7 DM Plant 5 5

8 MEE steam condensate

35 35

9 Domestic 8 8

Total 493.7 414.2

S.No. Waste water generation Jan, 2019

Feb, 2019

March, 2019

April, 2019

May, 2019

June, 2019

1 LTDS 206 186 208 200 536 536

2 HTDS 453 408 492 170 1285 2542

Total 659 594 700 370 1821 3078

The Waste water generation quantities are within the permitted capacities.

13. a) Hazardous waste generation for the period from Jan, 2019 to June, 2019 is as follows:

S.No. Type of Hazardous waste Jan, 2019

Feb, 2019

March, 2019

April, 2019

May, 2019

June, 2019

1 Organic residue 18.9 15.7 15.6 4.6 30 37.4

2 Spent Carbon 3.1 2.8 2.7 0.0 0.0 21.1

3 MEE salts 45.3 42.6 66.8 25.1 94.4 183.0

4 Gypsum Disposed 403.5 389 404.5 443 737 1230

b) The industry has disposed the hazardous the following hazardous waste during the period from Jan, 2019 to June, 2019

S.No. Jan, 2019

Feb, 2019

March, 2019

April, 2019

May, 2019

June, 2019

1 Organic residue 22 0 -- 28.2 20.1 20

2 Spent Carbon 0.0 0 -- 0 0 0

3 MEE salts 0.0 0 66.8 145 77.5 71.4

4 Gypsum Disposed 293 294 443 582 820 1116

During inspection, at about 20 TPM of MEE salts and 6 tons of organic residue are stored in the industry premises, which are supposed to be disposed to TSDF & cement industries.

14. The existing industry is having 8 TPH coal fired boiler for generation of steam with multicyclone dust collectors followed by Bag filters as air pollution control equipment. The industry proposed to utilize the existing 8 TPH boiler for change of product mix. No additional boiler is proposed.

15. The industry provided 4 No of two stage scrubbers for 4 blocks for control of process emissions and provided online pH measuring facility with auto recorder system to the scrubbers. Due to change of product mix, the HCL process emissions is reduced from 180 kgs/day to 109 kgs/day.

16. The industry has 50 KLD solvent recovery unit and the industry reusing the recovered solvents. During inspection, the solvent recovery unit is not in operation at about 20 KLD spent solvent, which are to be recovered are stored in the tanks.

17. The industry requested the Board to change the name of the product i.e., MX-9000 (1,5-Bis-[2,6-dimethyl-4-(2-methyl-2-propenoxy) phenyl}-penta-(2,6-dimethyl-1,4-phenyleneoxide) as SA9000 due to market conditions. The request of the industry may be considered. Remarks:

1. The industry has provide digital flow meter with totalizer facility at outlet of stripper, inlet of MEE, MEE condensate, MEE concentrate inlet of ATFD and RO reject.

2. The industry has provided flow meter with totalizer facility at RO permeate pipeline before going to RO permeate storage time and also provided web camera focuses digital flow meters of LTDS, HTDS and RO permeate. But the industry shall suitably change the digital flow meter location to RO permeate storage tank location and also change the location of the web camera to RO permeate storage tank for real time monitoring of regular of RO permeate.

3. The industry not provided TOC analyses incompliance with the SOP for solvent recovery unit for spent sulfuric acid.

The CFE for change of product mix may be considered as the present proposal is reducing the water consumption, waste water generation, process emissions, hazardous waste generation with no increase in pollution load and production capacity. Industry may be called for personal presentation to review the proposal of change of product mix, water consumption, waste water generation, treatment and disposal.

CFE for change of product mix may be considered only after obtaining specific commitment on the above duly stipulating necessary conditions. 12) Head Office Remarks:

a) The industry has provided flow meter with totalizer facility at RO permeate pipeline before going to RO permeate storage time and also provided web camera focuses digital flow meters of LTDS, HTDS and RO permeate. But the industry shall suitably change the digital flow meter location to RO permeate storage tank location and also change the location of the web camera to RO permeate storage tank for real time monitoring of regular of RO permeate.

b) The industry not provided TOC analyses incompliance with the SOP for solvent recovery unit for spent sulfuric acid.

c) The Board in the earlier CFE order dt. 31.12.2018, under condition No. 17 “Solid waste / Hazardous waste”, accorded permission for handling Bio-medical waste, E-waste generation from Occupational Health Centre (OHC). But, in the proposal it was not mentioned. The industry has to clarify.

The item is placed before the CFE Committee for taking a decision.