GLOBAL CALCIUM PRIVATE LIMITED UNIT...
Transcript of GLOBAL CALCIUM PRIVATE LIMITED UNIT...
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PRE-FEASIBILITY REPORT ON ENVIRONMENTAL ASPECTS
PROPOSED EXPANSION
By Addition Of
100 TPA
ACTIVE PHARMACEUTICAL INGREDIENTS (API)
Within Existing Bulk Drug Unit
AT
GLOBAL CALCIUM PRIVATE LIMITED – UNIT III
# 19, 19B, SIPCOT Industrial Complex, Hosur – 635 126.
MARCH 2019
Pre-Feasibility Report GCPL-Unit III
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CONTENTS
1.0 EXECUTIVE SUMMARY ................................................................................................ 1
2.0 INTRODUCTION ............................................................................................................ 3
3.0 PROPOSED PROJECT ................................................................................................... 3
4.0 PROJECT LOCATION .................................................................................................... 4
5.0 RAW MATERIALS CONSUMPTION .......................................................................... 6
6.0 MANUFACTURING PROCESS .................................................................................. 10
7.0 RAW WATER REQUIREMENT .................................................................................. 58
8.0 ENERGY CONSUMPTION .......................................................................................... 60
9.0 WORK FORCE ............................................................................................................... 60
10.0 EXISTING ENVIRONMENTAL SCENARIO ........................................................... 60
10.1 Air Environment .................................................................................................. 60
10.2 Noise Environment ............................................................................................. 63
10.3 Water Environment ............................................................................................ 63
10.4 Soil Environment ................................................................................................. 66
11.0 WASTE & WASTE MANAGEMENT .......................................................................... 69
11.1 Air Pollution ........................................................................................................... 69
11.2 Wastewater Generation ..................................................................................70
11.3 Solid Wastes ......................................................................................................... 71
12.0 CONCLUSION ............................................................................................................... 71
Pre-Feasibility Report 1 GCPL-Unit III
1.0 EXECUTIVE SUMMARY
1.1 Proposed Project
Global Calcium Private Limited Unit – III has proposed to expand its facility by
installing an additional unit to produce Active Pharmaceutical Ingredient in addition
to existing facility producing mineral salts of Gluconates, Lactates, Lactobionate etc.
1.2 Project Location
The proposed expansion will be carried out within the existing premises of the plant at
19 & 19B, SIPCOT Industrial Complex, Hosur, Krishnagiri District, Tamil Nadu.
1.3 Project Proponent
Global Calcium Private Limited is one of the major producers of Nutrition
Supplements/Additives in the Domestic Market as also in the Global Market. These
Nutrition Supplements are widely used for human consumption as also for veterinary
care.
1.4 Manufacturing Process
Global Calcium Private Limited – Unit III, has proposed to install an API unit within the
existing plant premises.
The existing process of producing Mineral Salts involves neutralization of respective
salts with Gluconic Acid followed by filteration, crystallization, drying and packing.
In the proposed production of Active Pharmaceutical Ingredient (API), the respective
raw material based on the product are hydrolysed in a reactor and then extracted,
centrifuged, and dried.
1.5 Production Capacity
The product at present produced is mineral salts of 1020 TPA (Conversion Process) &
1034 TPA (By Spray Drier Process).
The proposed expansion is to produce 100 TPA of Active Pharmaceutical Ingredients.
1.6 Land Area
The details of Land utilization is as follows
Sl
No Particulars Existing
(in ha.)
Proposed
Addition
(in ha.)
After
Expansion
(in ha.)
1 Built up area 0.273 0.054 0.327
2 Solid waste storage / disposal area 0.237 - 0.237
3 Green Belt / Irrigation area 0.266 - 0.266
4 Road 0.190 - 0.190
5 Vacant area 0.054 - -
Total area 1.02 1.02
Pre-Feasibility Report 2 GCPL-Unit III
1.7 Raw Water Source & Usage
Upon expansion, the total water requirement will be 121.5 KLD. Out of which, 68.7 KLD
through recycling, remaining 52.8 KLD (fresh water requirement) met from SIPCOT
Supply.
1.8 Solid Waste Generation & Method of Disposal
The quantity of solid waste generation and disposal methods for existing and proposed
expansion are given in the following table.
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
1.9 Man Power Requirement
The existing work force of 70 Nos. additional man power requirement will be 80 Nos.
Upon expansion the total work force will be 150 Nos.
1.10 Estimated Project Cost
The total project cost for the proposed expansion is ` 10 Crores.
1.11 Pollution Control Cost
The total pollution control cost for proposed plant is ` 2.5 Crores.
Pre-Feasibility Report 3 GCPL-Unit III
2.0 INTRODUCTION
As an EU-GMP certified global company and an established hallmark for pharmaceutical
standards, Global Calcium has stood the test of time since its inception in 1979 as
Calcium India. Today, Global Calcium represents the true hallmark of quality when it
comes to pharmaceutical products.
Global Calcium is backed by an excellent management team comprising of industry
specialists, technocrats, entrepreneurs and business specialists bringing in strong
domain expertise in the pharmaceutical industry.
Global Calcium prioritizes Research and Development over everything else; companies
today are well aware that only with superior R & D can they continue to innovate and
deliver international-quality products. The focused R&D effort and initiatives are behind
the cost advantages that the end customers enjoy.
Global Calcium's goal is to develop genuine business partnership with clients to result
in a win-win strategy. By combining its resources and expertise with its strategy
pattern Global Calcium achieves product development objectives and successful
completion of quality health formulations and products.
Global Calcium is one of the major producers of Nutrition Supplements/Additives in the
Domestic Market as also in the Global Market. These Nutrition Supplements are widely
used for human consumption as also for veterinary care.
3.0 PROPOSED PROJECT
Global Calcium Private Limited Unit – III has proposed to expand its facility by
installing an additional unit to produce Active Pharmaceutical Ingredient in addition
to existing facility producing mineral salts of Gluconates, Lactates, Lactobionate etc.
The proposed expansion will be carried out within the existing premises of the existing
plant site itself.
Pre-Feasibility Report 4 GCPL-Unit III
The production details at present are as follows.
Processing in the Plant
by Conventional Process Pharmaceutical bulk drugs and
chemicals such as
Mineral salts of Gluconates, Citrates, Lactates, Lactobionates,
Fumarates, Orotates, Ascorbates, Aspartates, Pidolates, Bis
Glycinate, Calcium D Saccharate, Pyrophosphates, etc
1020
by spray drier process
Calcium Glubionate , Calcium Borogluconate, Calcium lacto
Gluconate, Gluconates, Aspartates, Pidolates and other Mineral
Salts
1034
It is now proposed to expand by additionally installing a unit to produce Active
Pharma Ingredients (API) Products.
API Products (Active Pharma Ingredients) such as
Iron sucrose, Calcium dobesylate, Tiemonium methyl sulphate,
Ethamsylate, Tolperisone Hcl, Glycerophosphates, Fenspride
Hydro Chloride, Clozapine, Nifuroxide, Oxetacaine, Benfotiamine,
Calcium folinate, Trimetazidine Hydro chloride, Calcium methyl
Folate, Ubiquinol Acetate, Strontium ranelate, Phenyramidol
Hydrochloride, Iron Sorbitol Complex, , Naftifine Hydrochloride,
Esmolol Hydrochloride, L- Methyl Folate, Minoxidil, Mebeverine
Hydrochloride, Terbinafine etc
100
4.0 PROJECT LOCATION
The proposed expansion is within the premises of the existing plant site located at #
19, 19B SIPCOT Industrial Complex, Hosur – 635 126, Tamil Nadu, which is a notified
industrial estate in Tamil Nadu.
State Industries Promotion Corporation of Tamil Nadu (SIPCOT) Limited, a fully
government owned premier institution, established in the year 1972, has been a
catalyst in development of small, medium and large scale industries in Tamil Nadu.
Total Area of the SIPCOT Complex Phase-1 at Hosur is 1235.86 Acres, which is well
connected by National Highway (NH-7) ie Chennai - Bangalore Highway. SIPCOT has
also established all requisite infrastructure to supply water to all the industries, and
have also established an exclusive substation to ensure uninterrupted power supply.
The Location Map is as shown in Fig.1.0.
Pre-Feasibility Report 5 GCPL-Unit III
Fig 1.0 LOCATION MAP
Pre-Feasibility Report 6 GCPL-Unit III
5.0 RAW MATERIALS CONSUMPTION
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
Pre-Feasibility Report 7 GCPL-Unit III
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 phasphate 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
Pre-Feasibility Report 8 GCPL-Unit III
46 Cannamyl chloride 600.0 Solid
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
Pre-Feasibility Report 9 GCPL-Unit III
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
Pre-Feasibility Report 10 GCPL-Unit III
6.0 MANUFACTURING PROCESS
Existing
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
PACKING MILLING DRYING CENTRIFUGING
GLUCONO DELTA LACTONE + CaCO3 + WATER
(NEUTRALISATION) FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
Pre-Feasibility Report 11 GCPL-Unit III
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,
concentrated, crystallised, centrifuged, dried, milled and packed.
Alternate process
NEUTRALISATION FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
NEUTRALISATION FILTRATION
CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
GLUCONIC ACID + SODIUM
CARBONATE / BICARONATE
(NEUTRALISATION) FILTRATION SIEVING
PACKING
DRYING
Pre-Feasibility Report 12 GCPL-Unit III
Potassium Gluconate
Gluconic acid brought from the market is neutralised with Potassium carbonate,
filtered, concentrated, crystallised, centrifuged, dried, milled and packed.
Alternate process for the manufacture of Potassium Gluconate
Gluconic acid is neutralised with Potassium carbonate / Potassium Bicarbonate,
filtered, concentrated, crystallised, centrifuged, dried, milled and packed.
Alternate process
NEUTRALISATION FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
NEUTRALISATION FILTRATION
CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
GLUCONIC ACID +
POTASSIUM CARBONATE /
BICARONATE
(NEUTRALISATION)
FILTRATION SIEVING
PACKING
DRYING
Pre-Feasibility Report 13 GCPL-Unit III
Magnesium Gluconate
Gluconic acid brought from the market is neutralised with Magnesium carbonate,
filtered, concentrated, crystallised, centrifuged, dried, milled and packed.
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
NEUTRALISATION FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
NEUTRALISATION FILTRATION
CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
GLUCONIC ACID +
MAGNESIUM CARBONATE
(NEUTRALISATION) FILTRATION SIEVING
PACKING
DRYING
Pre-Feasibility Report 14 GCPL-Unit III
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
NEUTRALISATION FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
NEUTRALISATION FILTRATION
CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
GLUCONIC ACID + ZINC
CARBONATE / ZINC OXIDE
(NEUTRALISATION) FILTRATION SIEVING
PACKING
DRYING
Pre-Feasibility Report 15 GCPL-Unit III
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,
concentrated, crystallised, centrifuged, dried, milled and packed.
Alternate process
NEUTRALISATION FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
NEUTRALISATION FILTRATION
CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
CONCENTRATION
GLUCONIC ACID +
MANGANESE CARBONATE /
MANGANESE OXIDE
(NEUTRALISATION)
FILTRATION SIEVING
PACKING
DRYING
Pre-Feasibility Report 16 GCPL-Unit III
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.
NEUTRALISATION FILTRATION CRYSTALLISATION
PACKING MILLING DRYING CENTRIFUGING
BLENDING SIEVING PACKING
MIXING SIEVING PACKING FILTERING DRYING
Pre-Feasibility Report 17 GCPL-Unit III
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 manufacture of Calcium Lacto Gluconate
Calculated quantities of Calcium Lactate and Calcium Gluconate are mixed in DM water,
filtered, dried, sieved and packed.
3. Alternate Process for the manufacture of Calcium Lacto Gluconate
Calculated quantities of Gluconic Acid, Lactic Acid are reacted with calcium carbonate,
filtered, dried, sieved and packed.
4. Alternate Process for the manufacture of Calcium Lacto Gluconate
MIXING SIEVING PACKING FILTERING DRYING
BLENDING SIEVING PACKING
GLUCONIC ACID + LACTIC
ACID + CaCO3
(NEUTRALISATION) FILTRATION SIEVING
PACKING
DRYING
GLUCONO DELTA LACTONE +
LACTIC ACID + CaCO3
(NEUTRALISATION) FILTRATION SIEVING
PACKING
DRYING
Pre-Feasibility Report 18 GCPL-Unit III
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
PACKING MILLING DRYING CENTRIFUGING
VACCUM
CONCENTRATION
LACTOSE,
SODIUM BROMIDE,
CALCIUM CARBONATE,
DM WATER
Pre-Feasibility Report 19 GCPL-Unit III
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 :
BLENDING
SIEVING PACKING
CALCIUM
GLUCONATE + BORIC
ACID + DISSOLVED IN
DM WATER
FILTERED DRIED
PACKED SIEVED
CALCIUM
GLUCONATE +
FERROUS SULPHATE
+ DM WATER
FILTERATION CONCENTRATION
PACKING MILLING DRYING
Pre-Feasibility Report 20 GCPL-Unit III
Manufacturing Process
Proposed
1 IRON SUCROSE
Ferric Chloride is dissolved in water and sodium bicarbonate solution is added to
precipitate ferric hydroxide which is filtered.
Above ferric hydroxide is mixed with sucrose and heated to get iron sucrose in solution.
Which is concentrated to get thick mass which is added with vigorous stirring to DNS
and then methanol to precipitate iron sucrose solid. This is centrifuged and slurried with
DNS and acetone again to remove the impurities. The wet material is dried under
vacuum, pulverized, redried, milled, blended as needed and packed.
Raw material:
Ferric Chloride
Sodium carbonate
Sucrose
DNS denatured spirit
Methanol
Acetone
Raw material consumption per kg of output
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
Pre-Feasibility Report 21 GCPL-Unit III
PROCESS FLOW CHART
Sodium carbonate
solution
MLR collection
Heat
DNS
MLR collection
methanol
DNS
Acetone MLR collection
Water + Ferric Chloride
Filtration of Ferric hydroxide
Ferric hydroxide Cake + Sugar
Concentrated
Filtration
Filter Mass
Filtration
Vacuum Drying
Milling, Blending & Packing
Pre-Feasibility Report 22 GCPL-Unit III
2. CALCIUM DOBESYLATE
Stage-I: Sulphuric acid is added to a suspention of hydroquinone in ethylene di
chloride. After the sulfonation, water is added and aqueous layer separated.
Stage-II: aqueous layer is neutralized with a slurry of calcium carbonate in water,
centrifuged to separate calcium sulfate.
Liquid from centrifuge is concentrated, chilled, the product filtered and washed with
isopropanol and dried.
Raw material:
Hydroquinone
Sulphuric acid
Calcium carbonate
Ethylene di chloride
Isopropanol
Raw material consumption per kg of output
Hydroquinone = 1.2 kg
Sulphuric acid = 1.6 kg
Calcium carbonate = 1.6kg/kg
Ethylene di chloride = 4L/kg
Isopropanol = 2L/kg
Pre-Feasibility Report 23 GCPL-Unit III
PROCESS FLOW CHART
Stage-1
sulphuric acid
layer separation
Stage-II
calcium carbonate
centrifuge
concentrated
chilled
isopropanol
Hydroquinone + ethylene di chloride
Aqueous layer
Liquid from centrifuge
Crystallisation
Drying
Centrifugation
Milling, Blending & Packing
Residue
Pre-Feasibility Report 24 GCPL-Unit III
3. TIEMMONIUM METHYL SULPFATE (TMS)
Morpholine is reacted with 2-acetyl thiophene and p-formaldehyde in the presence of
hydrochloric acid in denatured spirit (DNS) to get the corresponding mannich base as
HCl salt. The above HCl salt is basified in toluene to get the corresponding mannich
ketone base. This is reacted with phenyl magnesium bromide in tetrahydrofuran to get
tiemmonium hydrochloride which is purified using methanol slurry. The pure
hydrochloride is converted to base and treated with dimethyl sulfate in acetone to get
the tiemmonium methyl sulfate. This is dried in a vacuum oven, milled, blended and
packed.
Raw material:
Morpholine
2- Acetyl thiophene
P-Formaldehyde
Hydrochloric acid
Denatured spirit (DNS)
Phenyl magnesium bromide
Dimethyl Sulfate
Tetrahydrofuran
Methanol
Toluene
acetone
Raw material consumption per kg of output
Morpholine = 1 kg / kg
2- Acetyl thiophene = 1.5 kg / kg
P-Formaldehyde =0.7 kg / kg
Hydrochloric acid = 5.7 kg / kg
Denatured spirit (DNS) = 6L / kg
Phenyl magnesium bromide =2.3 kg / kg
Dimethyl Sulfate =0.5 kg / kg
Methanol = 3L/kg
Tetrahydrofuran = 2L/kg
Toluene = 8 L/kg
Acetone = 5L/kg
Pre-Feasibility Report 25 GCPL-Unit III
PROCESS FLOW CHART
Con. HCl
Reflux
MLR collection
Phenyl magnesium bromide
Con. HCl
Methanol MLR collection
Dimethy sulphate
MLR collection
Morpholine + 2- Acetyl thiophene +
P-Formaldehyde +DNS
Cool, Centrifugation, Basification
Ketone Base
Quenching ice water
Centrifugation
Basification with Ammonia
Centrifugation
Vacuum Drying
Milling, Blending & Packing
Pre-Feasibility Report 26 GCPL-Unit III
4 ETHAMSYLATE
Stage-I: Sulphuric acid is added to a suspention of hydroquinone in ethylene di
chloride. After the sulfonation, water is added and aqueous layer separated.
Stage-II: aqueous layer is neutralized with diethylamine, concentrated, chilled, the
product filtered and washed with isopropanol and dried.
Raw material:
Hydroquinone
Sulphuric acid
Diethylamine
Ethylene di chloride
Isopropanol
Raw material consumption per kg of output
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
Pre-Feasibility Report 27 GCPL-Unit III
PROCESS FLOW CHART
Stage-I:
Suphuric acid
water
layer separation
stage-II
diethylamine
concentration
isopropanol
hydroquinone + ethylene di chloride
Sulphonated mass
Aqueous layer
Crystallisation
Drying
Centrifugation
Milling, Blending & Packing
Chill, residue
Pre-Feasibility Report 28 GCPL-Unit III
5 TOLPERISONE HCl
Mixture of 4-methyl propiophenone, piperidine, and hydrochloric acid heated to reflux
in 1,3-dioxalone. After the reaction is over, diluted with ethyl acetate and chilled with
stirring. Product formed is centrifuged, washed with ethyl acetate. The crude product
is purified with methanol and ethyl acetate using charcoal.
Raw material:
1.4-methyl propiophenone
2. piperidine
3.1,3-dioxalone
4. conc. hydrochloric acid
5. ethyl acetate
6. methanol
Raw material consumption per kg of output
1.4-methyl propiophenone 1.0 kg
2. piperidine 0.6 kg
3.1,3-dioxalone 1.5 kg
4. conc.hydrochloric acid 0.025 L
5. ethyl acetate 3.0 L
6. methanol 1.0 L
Pre-Feasibility Report 29 GCPL-Unit III
PROCESS FLOW CHART
Reflux
chill
stage-1
charcoal
filter
4-methyl propiophenone+piperidine+
HCl + 1,3-dioxolane
Dilute with ethyl actate
Centrifugation
Dissolve stage-1 in methanol
centrifugation
Filtrate , concentrate, add ethyl
acetate, chill
Vacuum drying
Milling, Blending & Packing
Pre-Feasibility Report 30 GCPL-Unit III
6. a. CALCIUM GLYCEROPHOSPHATE
Stage – I: Epichlorohydrin is hydrolised with dilute acid, and reacted with Tri sodium
phosphate, to get Crude sodium Glycerophosphate.
Stage –II : To the Above crude Sodium Glycerophosphate solution , Calcium chloride is
added to get Crude Calcium Glycerophosphate
Stage – III : crude Calcium Glycerophosphate is washed with DNS: Water mixture to
get Pure Calcium Glycerophosphate, which is centrifuged and dried.
Raw material:
1. Epichlorohydrin
2. Trisodium phosphate
3. Calcium chloride
4. Denatured spirit (DNS)
Raw material consumption per kg of output
1. Epichlorohydrin = 1.5 kg / kg
2. Trisodium phosphate = 6.0 kg / kg
3. Calcium chloride = 2.0 kg / kg
4. Denatured spirit (DNS) = 5.0 L / kg
Pre-Feasibility Report 31 GCPL-Unit III
PROCESS FLOW CHART
Stage - I
Reflux
Hot condition
Stage -II
Calcium chloride
Stage -III
DNS: Water
Epichlorohydrin + water
Reaction with Trisodium phosphate
Charcoal treatment & Filtration
Reaction with calcium chloride
Drying
Centrifugation & Slurry wash
Milling, Blending & Packing
Pre-Feasibility Report 32 GCPL-Unit III
6.b. MAGNESIUM GLYCEROPHOSPHATE
Stage – I: Epichlorohydrin is hydrolised with dilute acid, and reacted with Tri sodium
phosphate, to get Crude sodium Glycerophosphate.
Stage –II : To the Above crude Sodium Glycerophosphate solution ,Magnesium
chloride is added to get Crude Magnesium Glycerophosphate
Stage – III : crude Magnesium Glycerophosphate is washed with DNS: Water mixture
to get Pure Magnesium Glycerophosphate, which is centrifuged and dried
.
Raw material:
4. Epichlorohydrin
5. Trisodium phosphate
6. Magnesium chloride
7. Denatured spirit (DNS)
Raw material consumption per kg of output
8. Epichlorohydrin =1.5 kg / kg
9. Trisodium phosphate = 6 kg / kg
10. Magnesium chloride = 3 kg / kg
11. Denatured spirit (DNS) = 5L / kg
Pre-Feasibility Report 33 GCPL-Unit III
PROCESS FLOW CHART
Stage - I
Reflux
Hot condition
Stage -II
Magnesium chloride
Stage -IV
DNS: Water
Epichlorohydrin + water
Reaction with Trisodium phosphate
Charcoal treatment & Filtration
Reaction with Magnesium chloride
Drying
Centrifugation & Slurry wash
Milling, Blending & Packing
Concentration
Pre-Feasibility Report 34 GCPL-Unit III
6. c. SODIUM GLYCEROPHOSPHATE
Stage – I: Epichlorohydrin is hydrolised with dilute acid, and reacted with Tri sodium
phosphate, to get Crude sodium Glycerophosphate solution which is concentrated and
filtered to get Crude sodium Glycerophosphate
Stage – II : crude Sodium Glycerophosphate is washed with DNS: Water mixture to
get Pure Sodium Glycerophosphate, which is entrifuged and dried
.
Raw material:
1. Epichlorohydrin
2. Trisodium phosphate
3. Denatured spirit (DNS)
Raw material consumption per kg of output
4. Epichlorohydrin =1 kg / kg
5. Trisodium phosphate = 6 kg / kg
6. Denatured spirit (DNS) =5L / kg
Pre-Feasibility Report 35 GCPL-Unit III
PROCESS FLOW CHART
Stage - I
Reflux
Hot condition
DNS
Stage -II
DNS: Water
Epichlorohydrin + water
Reaction with Trisodium phosphate
Charcoal treatment & Filtration
Crystallisation
Drying
Centrifugation & Slurry wash
Milling, Blending & Packing
Concentration
Pre-Feasibility Report 36 GCPL-Unit III
7 FENSPIRIDE HYDROCHLORIDE
MANUFACTURING FLOWCHART:
Stage-1:
1-(2-phenylethyl)-4-piperidone
Hydrochloric acid
Water, centrifuge, dry
Stage-II : Fenspiride Hydrochloride Crude
Zinc Dust
basify with Aq. ammonia
Dichloromethane
Concentration
Toluene, Diethyl carbonate
water, toluene
acidify, Hydrochloric
acid
cool, centrifuge, dry
Stage-III: Purification
Stage-II
Heat
Acetone
Cool & Centrifuge,
Nitromethane+ DMSO +
Potassium Carbonate, 0 deg.C
Stage-1
Methanol + Stage-1+
Hydrochloric acid, <5 deg.C
Dichloromethane layer
toluene layer
Stage-II
Methanol
Concentrate
Drying, milling, Sieving+ packing
Residue
Pre-Feasibility Report 37 GCPL-Unit III
Manufacturing process for the Fenspiride Hydrochloride:
Stage-I: 4-(nitromethyl)-1-phenethylpiperidin-4-ol is prepared by reacting 1-(2-
phenylethyl)-4-piperidone with nitromethane and potassium carbonate in
dimethylsulfoxide. stage-1 is isolated by quenching in water Centrifuging.
Stage-II: Fenspiride hydrochloride crude is prepared by the reduction of stage-I with
zinc dust and hydrochloric acid, basification with aqueous ammonia and extracting with
dichloromethane. Dichloromethane extract is concentrated to get 4-(aminoethyl)-1-
phenylpiperidin-4-ol, which is reacted with diethylcarbonate in the presence of sodium
methoxide to get Fenspiride base. This is treated with Hydrochloric acid to get
Fenspiride hydrochloride crude.
Stage-III: Fenspiride HCl crude dissolved in methanol , treated with Activated carbon.
filtered, filtrate concentrated completely, Acetone is added , solid centrifuged, dried
under vacuo <60 deg.C , milled ,sieved and packed.
8 CLOZAPINE :
MANUFACTURING FLOW CHART
2-chloro benzoic acid
reduction
water +sodium dithionate
stage-1
cyclisation, xylene
stage-2
N-methylpiperazine, TiCl4
stage-3
recrystallisation
4-chloro-2-nitro aniline
+potassium carbonate +DMF
2-( 4-chloro -2-amino diphenylamino)benzoic
acid
8-chloro-5H-benzo-[b,e][1,4]diazepine-11-
10H-one
crude clozapine
pure clozapine
Drying, sieving and packing
Pre-Feasibility Report 38 GCPL-Unit III
Brief process description:
Stage-1:
4-chloro-2-nitro aniline is reacted with 2-chloro bezoic acid and th e resulting product
is reduced in-situ with sodium dithionate in water to get 2-( 4-chloro -2-amino
diphenylamino)benzoic acid stage-1
Stage-2:
Stage-1 is cylised in refluxing xylene to get 8-chloro-5H-benzo-
[b,e][1,4]diazepine-11-10H-one
Stage-3:
Stage-2 is reacted with N-methyl piperazine in presence of titanium tetrachloride to
get crude clozapine (stage-3)
Stage-4: pure clozapine
Crude clozapine is purified to pure clozapine by dissolving in methanol , charcolising,
filtering, concentrating and cooling. The product is centrifuged, dried under vacuum
below 60 deg.C , milled , sieved and packed.
9 NIFUROXAZIDE
MANUFACTURING FLOW CHART:
Synthesis of Nifuroxazide:
Nitrofurfural diacetate
Heat
4-hydroxy benzohydrazide
Hydrochloric acid
Heat & Cool
Centrifuge
Methanol
Centrifuge
Manufacturing procedure for Nifuroxazide:
Nitrofufural Diacetate reacts with 4-hydroxy benzohydrazide in the presence of sulfuric acid
in DNS to form the Nifuroxazide.
Water +Sulphuric acid+ DNS
Reaction mass
Reaction mass
Wet cake, reflux
Drying, milling, sieving, packing
Pre-Feasibility Report 39 GCPL-Unit III
10 OXETACAINE MANUFACTURING FLOW CHART:
Stage-I:
Sulfuric acid
water
Centrifuge, dry
Stage-II: Methylation
Dimethyl sulfate
Potassium hydroxide
Heating
Water
Extraction & Distillation
Stage-III:
PEG-400
heating Sodium Hydroxide
dichloro ethane
Water
Extraction
Layer separation
Chloroacetyl chloride
Sodium hydroxide
Extraction & Distillation
Dimethyl benzyl carbinol +
Acetonitrile
Stage-I+ Toluene
Dimet
stage-1
Reaction Mass
Residue
Stage-II
Reaction Mass
Organic layer
Residue
Pre-Feasibility Report 40 GCPL-Unit III
Stage-IV: Oxetacaine crude
Etanol amine Toluene
Sodium Hydroxide
Heating
Water
Extraction , layer separation
Hydrochloric acid
Extraction, layer separation
Ammonia
Centrifuge, dry
Stage-V: Purification
Isopropyl alcohol
Water
Centrifuge
Manufacturing Process of Oxetacaine:
Stage-1: Dimethyl benzyl carbinol is reacted acetonitrile and sulfuric acid to get
stage-I.
Stage-I1: Stage-I methylated with dimethyl sulfate in the presence of potassium
hydroxide in toluene to stage-II.
Stage-II1: Stage-II hydrolyzed with sodium hydroxide and reacted with chloroacetyl
chloride to stage-III.
Stage-IV: Stage-III reacted with ethanol amine in the presence of sodium hydroxide
in toluene to stage-IV (Oxetacaine crude).
Stage-V: Oxetacine crude crude purified using Isopropyl alcohol and water to get
pure Oxetacaine
11 BENFOTIAMINE
Mixture of thiamine HCl and orthophosphoric acid is heated and phosphorous pentoxide
is added slowly over a period. Diluted by adding water and Hydrolysed by heating to
reflux
The above solution is basified with sodium hydroxide and treated with benzoyl chloride
in methylene di chloride at low temperature. After the reaction, centrifuged to remove
inorganics, the MLR is concentrated and filtered. The filtrate is acidified to get the
crude benfotiamine which is centrifuged and washed with water.
crude product is dissolved in dilute sodium hydroxide, charcolised, filtered, acidified to
get the pure product which is centrifuged, washed with water, methanol and spin dried.
Residue
Reaction
Organic layer
Acidic layer
stage-IV
Stage-IV
Drying, milling, sieving, packing
Pre-Feasibility Report 41 GCPL-Unit III
The wet material is dried under vacuum, pulverized, milled, blended as needed and
packed.
Raw material:
1. thiamine HCl
2.orthophosphoric acid
3.phosphorous pentoxide
4.Sodium hydroxide
5.benzoyl chloride
6.Hydrochloric acid
7.methylene chloride
8.methanol
Raw material consumption per kg of output
1. thiamine HCl 2.5 kg
2.orthophosphoric acid 3.5 kg
3.phosphorous pentoxide 2.5 kg
4.Sodium hydroxide 2.5 kg
5.benzoyl chloride 1.5 kg
6.Hydrochloric acid 2.5 L
7.methylene chloride 5.0 L
8.methanol 2.0 L
PROCESS FLOW CHART
Phosphorous pentoxide
heat
water
reflux, cool
benzoyl chloride
in DCM
hydrochloric acid
Hydrochloric acid
Thiamine HCl + orthophosphoric
acid
Reaction mixture
Reaction mixture+ sodium
hydroxide
Centrifugation
Above solid + aq. sodium hydroxide
Charcoalise, filter
Centrifuge, MLR concentrate
Pre-Feasibility Report 42 GCPL-Unit III
12 CALCIUM FOLINATE
Folic acid dissolved in water and treated with sodium borohydride under cooling. The
mixture is quenched into hydrochloric acid and then formylated using formic acid. The
reaction solution is concentrated under vacuum and centrifuged to get stage-1(formyl
folic acid). Stage-1 is reacted with triethylamine in water and then converted to the
corresponding calcium salt using calcium chloride. The product is precipitated by adding
DNS. The crude product is purified using water and DNS. Washed with acetone and
dried. The wet product is dried under vacuum, milled and sieved and packed.
Raw material:
1. folic acid
2. sodium borohydride
3. conc. HCl
4. triethyl amine
5. calcium chloride
6. DNS
7.acetone
8.formic acid
9. Methanol
Raw material consumption per kg of output
1. folic acid 2.5 kg
2. sodium borohydride 5 kg
3. conc. HCl 7 L
4. triethyl amine 2 L
5. calcium chloride 2 kg
6. DNS 75 L
7.acetone 5 L
8.formic acid 70 L
9. methanol 5L
PROCESS FLOW CHART
Sodium boro hydride
Centrifugation
Milling, Blending & Packing
Vacuum drying
Folic acid in water
Pre-Feasibility Report 43 GCPL-Unit III
Formic acid
Stage -1
triethylamine
DNS
calcium chloride
Quench into HCl
Filtration, concentration
Centrifugation
Stage-1 in water
Drying under vacuum
Milling, sieving Blending & Packing
Reaction mixture
centrifugation
recrystallisation
centrifugation
Pre-Feasibility Report 44 GCPL-Unit III
13. TRIMETAZIDINE HYDROCHLORIDE
Stage-I: Synthesis of Trimetazidine Hydrochloride crude
Piperazine
5% Palladium on
Carbon
Hydrogenator
Centrifuge, Concentrate
Toluene,water
Extraction, layer separation
isopropanolic HCl,cool
Centrifuge, dry
Stage-II: Purification of Trimetazidine crude
Methanol
activated carbon
heat, filter
concentrate
Acetone
Centrifuge
Manufacturing procedure for Trimetazidine Hydrochloride:
Stage-I: 2,3,4-trimethoxy benzaldehyde and piperazine is condensed and reduced
using Palladium on carbon and Hydrogen gas and isolated as , trimetazedine
hydrochloride crude
Stage-II: Stage-I purified by dissolving in methanol, charcolisation, filtration,
concentration. pure Trimetazidine hydrochloride. is isolated by adding acetone.
2,3,4-trimethoxy
benzaldehyde
+ Methanol
Reaction mass
Residue
Toluene Layer
Stage-I
Stage-I
filtrate
Residue
Drying, Milling, Sieving,
packing
Pre-Feasibility Report 45 GCPL-Unit III
14 CALCIUM METHYLFOLATE
MANUFACTURING FLOWCHART:
Stage-I: Synthesis of Calcium Methylfolate crude
Sodium Hydroxide
sodium borohydride
acidification, centrifugation
Sodium Borohydride
Formaldehyde
acidification, centrifugation
Calcium chloride
Centrifuging ,drying
Stage-II: Purification of Calcium methylfolate:
Water
hydrochloric acid,
Centrifuge
Sodium hydroxide
Calcium chloride
calcium chloride
Centrifuge
Manufacturing process for Calcium methylfolate:
Stage-I: A solution of Folic acid in sodium hydroxide is reduced with Sodium
borohydride to get tetrahydrofolate, which is reacted with formaldehyde and reduced
again with sodium borohydride and then treated with calcium chloride to get Calcium
methylfolate crude.
Stage-II: methyl folic acid is precipitated by acidification of the crude product
which is redissolved in Sodium hydroxide, charcoalised, filtered and reprecipitated
as pure calcium methyl folate by adding filtered calcium chloride solution.
Stage-I
solid +water
Process water+ Folic acid
Centrifugate
Drying, milling, sieving, packing
Centrifugate
crude CaMeF
Pre-Feasibility Report 46 GCPL-Unit III
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.
16. STRONTIUM RANELATE
Stage-I: ethyl acetone dicarboxilate is made by reacting citric acid with chlorosulfonic
acid in methylene chloride
Stage – II: ethyl acetone dicarboxilate is condensed with , Malano nitrile and Sulphur
in presence of triethylamine to get stage-II
Stage –III: Stage –II is reacted with Methyl bromoacetate and Potassium carbonate
in Acetone, and to get alkylated Stage –II.
Stage –IV; Stage –III reacted with strontium hydroxide in water under reflux condition
to get the final product which is washed with water, dried, milled and packed.
Raw material:
Triethylamine/Morpholine,
Methanol,
Malano nitrile
Sulphur
Acetone,
Potassium carbonate and
Methyl bromoacetate
Strontium hydroxide
isopropanol
Coenzyme Q10
n- heptane layer
residue
Drying, Milling, sieving, Packing
Pre-Feasibility Report 47 GCPL-Unit III
Raw material consumption per kg of output
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
PROCESS FLOW CHART
Stage - I
Citric acid
Water
Stage - II
Hot condition
Water
Stage -III
Hot condition
Methylene dichloride +
Chlorosulphonic acid
Quenching
Morpholine + methanol +
Malano nitrile + Suphur
Quenching
Acetone + Potassium carbonate +
Methyl bromoacetate
Filtration
Filtration & Concentration
Pre-Feasibility Report 48 GCPL-Unit III
Stage -IV
Water
Hot condition
17. PHENYRAMIDOL HYDROCHLORIDE
Stage-1: Synthesis of Phenyramidol Hydrochloride crude
Styrene Oxide
Water + Ethyl acetate
Extraction, layer separation
IPA.HCl
Centrifuge
2-Aminopyridine +DMF + Lithium
amide
Reaction mass
Organic layer
Phenyramidol Hydrochloride crude stage-1
Reaction with strontium hydroxide
Drying
Filtration
Milling, Blending & Packing
Pre-Feasibility Report 49 GCPL-Unit III
Stage-2 :Pure Phenyramidol Hydrochloride
Heating , filtration
Distillation
Acetone
Manufacturing process for Phenyramidol hydrochloride:
Stage-I: 2-Amino pyridine reacts with styrene oxide in the presence of lithium amide
to form the Phenyramidol hydrochloride crude.
Stage-II: Phenyramidol hydrochloride purified by using recrystallisation using
methanol and acetone to get pure Phenyramidol hydrochloride.
Methanol + Stage-1+activated
carbon
filtrate
Centrifugation, drying, milling
sieving & packing
Residue
Pre-Feasibility Report 50 GCPL-Unit III
18 IRON SORBITOL COMPLEX
MANUFACTURING FLOWCHART:
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
Pre-Feasibility Report 51 GCPL-Unit III
19 NAFTIFINE HYDROCHLORIDE:
Stage-I: Naftifine hydrochloride crude
Cinnamyl Chloride
Heat, centrifuge
Hydrochloric acid
Centrifuge, dry
Stage-II: Purification of Naftifine hydrochloride
Centrifuge, concentrate
Isopropyl alcohol
cool, Centrifuge
Manufacturing Procedure for Naftifine Hydrochloride.
Stage-I: N-Methyl –naphthyl- methanamine reacted with Cinnamyl chloride in the
presence of sodium bicarbonate in toluene to get Naftifine hydrochloride crude.
Stage-II: Stage-I purified by dissolving in methanol, charcolisation, filtration
concentration and isopropyl alcohol added to get Naftifine hydrochloride.
N-Methyl –naphthyl methanamine
+Sodium Bicarbonate+ Toluene
Stage-II + Methanol+activated carbon
stage-1
residue
Drying, Milling, sieving
centrifugate
Pre-Feasibility Report 52 GCPL-Unit III
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
Pre-Feasibility Report 53 GCPL-Unit III
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.
Pre-Feasibility Report 54 GCPL-Unit III
21 CALCIUM L-5- METHYLTETRAHYDROFOLATE MANUFACTURING FLOW
CHART:
Stage-I: Synthesis of Calcium Methylfolate
Sodium Hydroxide
Dissolution
conc. HCl Sodium boro hydride
Centrifuge
Formaldehyde
Sodium Borohydride
acidify Conc.HCl
Centrifuge
Calcium chloride
Centrifuge
Stage-II: Synthesis of Methylfolate salt with S-phenylethylamine
Hydrochloric acid
Centrifuge
Water
S-phenyl ethyl amine
Centrifuge
DNS
Centrifuge, dry
Stage-III: Synthesis of Calcium-L-Methylfolate Crude:
L-Cysteine
Centrifuge
DNS, Acetone
Centrifuge ,dry
Process water+ Folic acid
Filtrate
Reaction mass
Stage-1
Wet Cake
Product (wet cake)
stage-II
Filtrate
stage-1
Stage-II + Water + DNS
Reaction mass
Wet Cake
stage-III
Pre-Feasibility Report 55 GCPL-Unit III
Step-IV: Purification of Calcium-L-methylfolate:
Water
Heating & Cooling
Manufacturing process for the preparation of Calcium L-Methylfolate:
Stage-I: a solution of Folic acid in sodium hydroxide is reduced using Sodium
borohydride to tetrahydrofolate ,which is reaced with formaldehyde to get 5,10-
methyene tetrahydrofolate this is hydrolysed and reduced by sodium borohydride to
get Calcium DL- methylfolate.
Stage-II: Calcium DL- methylfolate reacted with S-phenyl methylamine to get the S
salt.
Stage-III: a solution of The above amine salt is treated with calcium chloride to get
L-methyl folate crude Stage-IV: Calcium L-Methylfolate crude is purified in water to
get pure Calcium L-methyl folate.
22 MINOXIDIL:
PROCESSES FLOW CHART
Stage-I: Preparation of Urea Hydrogen peroxide adduct
Urea
cool, centrifuge
Stage-II : Preparation of n-Oxide
a) Preparation of catalyst solution
Stage-I addition
b) Preparation of n-Oxide
Catalyst solution
Centrifuge
Stage-III
Reaction
Drying, milling, Sieving, Packing
Water+ Hydrogen peroxide
Stage-I
Carbinol+ Phthalic anhydride
Catalyst solution
Carbinol +2,4 diamino-6-
chloropyrimidine
Stage-II
cen
Pre-Feasibility Report 56 GCPL-Unit III
Stage-III: Preparion of Minoxidil crude
Distilation
Cooling & Centrifuge
Stage-IV: Purification
Heating
Cooling & Centrifuge
Manufacturing procedure of Minoxidil:
Stage-I: Preparation of Urea Hydrogen peroxide adduct
Hydrogen peroxide (50%) reacts with urea to form the urea hydrogen peroxide
adduct.
Stage-II: Preparation of n-Oxide
a) The catalyst solution is prepared by the reaction of urea hydrogen peroxide adduct
and phthalic anhydride in carbinol.
b) The above catalyst solution is added to a solution of 2,4 diamino-6-chloropyrimidine
in carbinol and warmed. The precipitated oxide is cooled and centrifuged.
Stage-III: Preparation of Minoxidil crude
Minoxidil crude is prepared by reacting Piperidine with stage-II at 60-70 deg C.
Product was isolated by centrifugation.
Stage-IV: Purification of Minoxidil crude
Minoxidil Crude purified by using carbinol to get pure Minoxidil.
23 MEBEVERINE HYDROCHLORIDE
MANUFACTURING FLOWCHART:
STAGE-I:- Synthesis of 4-bromobutyl-3,4-dimethoxybenzoate
1,4-Dibromobutane
High vaccum distillation
Piperidine+ Stage-II
Minoxidil crude + Methanol
Reaction mass
Stage-III
Drying, milling, sieving & packing
Veratric acid +
Potassium Hydroxide
Stage-I
Pre-Feasibility Report 57 GCPL-Unit III
STAGE-II: Synthesis of Mebeverine Hydrochloride crude
Methyl isobutyl
ketone
Potassium carbonate
Heat and filter
Water layer separation,
concentration
Centrifuge IPA. HCl
STAGE-III: Purification
Methyl isobutyl ketone
filter, concentrate and centrifuge
Manufacturing Procedure for Mebeverine Hydrochloride:
Stage-I : Veratric acid reacts with 1,4-dibromocompound in the presence of
potassium hydroxide to form the 4-bromobutyl-3,4-dimethoxybenzoate.
Stage-II : Stage-I reacts with 1-(4-methoxyphenyl)-2-ethylaminopropane in the
presence of sodium carbonate in Methyl isobutyl ketone to form the
Mebeverine Hydrochloride crude.
Stage-III: Stage-II purified by Methyl isobutyl ketone to get pure Mebeverine
Hydrochloride.
24 TERBINAFINE HYDROCHLORIDE:
Stage-I: Terbinafine hydrochloride crude
Chloro-6,6-dimethyl-2-hepten-4-yne
Heat, centrifuge
Hydrochloric acid
centrifuge, dry
1-(4-methoxyphenyl)-2-
ethylaminopropane
+
MBH-Stage-I
filtrate
residue
Mebeverine Hydrochloride
Crude
Mebeverine Hydrochloride
Crude +activated carbon
Packing, Drying, Milling, Sieving
N-Methyl –naphthyl methanamine
+Sodium carbonate+ Toluene
stage-1
centrifugate
Pre-Feasibility Report 58 GCPL-Unit III
Stage-II: Purification of Terbinafine hydrochloride
Centrifuge, concentrate
cool, Centrifuge
Manufacturing Procedure for Terbinafine Hydrochloride.
Stage-I: N-Methyl –naphthyl- methanamine reacted with 1-Chloro-6,6-dimethyl-2-
hepten-4-yne in the presence of sodium carbonate in toluene to get terbinafine
hydrochloride crude.
Stage-II: Stage-I purified by dissolving in methanol, charcolisation, filtration
concentration and isopropyl alcohol added to get terbinafine hydrochloride.
7.0 RAW WATER REQUIREMENT
A fullfledged ETP with 3 stage RO/Evaporator provided to recycle the treated waste
water in process, and make-up water met through SIPCOT supply.
The Plant operates at present, and will operate on expansion on Zero Discharge basis.
The entire waste water is, will be treated & reused. There will be no discharge of waste
water from the Plant.
The additional make-up water requirement is met through SIPCOT sources. There is no
drawal of ground or surface water from the plant.
Stage-II + isopropanol +activated carbon
residue
Drying, Milling, sieving
Pre-Feasibility Report 59 GCPL-Unit III
Water Balance 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
Pre-Feasibility Report GCPL
60
8.0 ENERGY CONSUMPTION
The details of existing and upon expansion power consumption and its source are as
follows:
Power Consumption
Source Existing Proposed Upon Expansion
Captive Windmill through
TNEB Grid
0.48 MW 0.32 MW 0.8 MW
Global Calcium has its own windmill, and the entire power required is met through this
windmill. The plant runs entirely on this green energy.
D.G. Sets of 180 KVA x 1, 380 KVA X 1, & Proposed 250 KVA X 1 capacity will be used only
during emergency or grid failure.
9.0 WORK FORCE
The existing work force of 70 Nos. proposed additional will be 80 Nos. and upon expansion
the total work force will be 150 Nos.
10.0 EXISTING ENVIRONMENTAL SCENARIO
10.1 Air Environment
Ambient air quality monitoring was carried out for 4-locations, one in the plant site and 3 in
different directions outside the plant site, the location of sampling station is given in the
following Table and as shown in Fig 2.0.
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61
Fig 2.0 Location of Ambient Air Quality Monitoring Stations
SA1
SA2
SA3
SA4
Pre-Feasibility Report GCPL – Unit III
62
Locations of Air Monitoring Stations
S. No. Code Sampling Station Direction to
proposed project
site
Distance from
proposed project
site (km)
1 SA1 Existing Plant - -
2 SA2 Santanapura Agraharam N 2.0
3 SA3 TVS Nagar SSW 3.5
4 SA4 Sanamavu SE 4.0
Summary of air quality data
Location Station Concentration g/Nm
3
Code SO2 NO
X PM
10 PM
2.5
Existing Plant SA1 12-31 23-38 28-66 15-22
Santanapura Agraharam SA2 8-16 9-18 37-58 16-24
TVS Nagar SA3 10-18 10-19 33-54 17-28
Sanamavu SA4 10-19 12-20 40-59 18-28
Overall 8-31 9-38 28-66 15-28
The Concentration of Ozone (O3), Lead (Pb), Carbon Monoxide (CO), Ammonia (NH3),
Arsenic (As), Nickel (Ni) Benzene (C6H6) and Benzo(a)Pyrene were Below Deductable
Level (BDL) in all locations.
Pre-Feasibility Report GCPL – Unit III
63
10.2 Noise Environment
Noise level measurements, with 5 minutes interval, in four corner of plant site were carried
out.
The observed ambient instantaneous noise levels at the plant site varied in the range of
63.5dB(A) – 72.2 dB(A) with most of the observed values less than 65 dB(A).
10.3 Water Environment
The ground/surface water quality in the study area, normally meets the desirable/essential
limits. The locations of water sampling stations marked in Fig 3.0 and the results are given
in the following Table.
Locations of Water Sampling Stations
S. No. Code Sampling Station Direction to
proposed project
site
Distance from
proposed project
site (km)
1 SW1 Existing Plant - -
2 SW2 Santaarpura Agraharam
(Borewell)
N 2.0
3 SW3 TVS Nagar (Borewell) SSW 3.5
4 SW4 Hosur (Lake) S 0.5
Pre-Feasibility Report GCPL – Unit III
64
Fig 3.0 Location of Water Sampling Stations
SW1
SW2
SW3
SW4
Pre-Feasibility Report GCPL – Unit III
65
Water Quality Data
S.No Parameters SW1 SW2 SW3 SW4
1 Colour (Hazen units) <1 <1 <1 <1
2 Odour Agreeable Agreeable Agreeable Agreeable
3 Total Suspended Solids, mg/l 16 15 17 18
4 Dissolved Solids mg/l 520 630 432 1205
5 PH Value 7.0 7.2 7.6 7.5
6 Temperature in oC 32 32 32 32
7 Oil & Grease, mg/l BDL BDL BDL BDL
8 Total Residual Chlorine, mg/l BDL BDL BDL BDL
9 Nitrate as No3, mg/l 14.14 16.12 0.06 22.10
10 B.O.D (3 days 27oC), mg/l 16 18 3 11
11 Arsenic (as As), mg/l BDL BDL BDL BDL
12 Mercury (as Hg), mg/l BDL BDL BDL BDL
13 Lead (as Pb), mg/l BDL BDL BDL BDL
14 Cadmium (as Cd), mg/l BDL BDL BDL BDL
15 Hexavalent Chromium (as
Cr+6), mg/l
BDL BDL BDL BDL
16 Total Chromium (as Cr), mg/l BDL BDL BDL BDL
17 Copper (as Cu), mg/l BDL BDL BDL BDL
18 Zinc (as Zn), mg/l 0.02 0.02 <0.01 0.05
19 Selenium (as Se), mg/l BDL BDL BDL BDL
20 Nickel (as Ni), mg/l BDL BDL BDL BDL
21 Boron (as B), mg/l BDL BDL BDL BDL
22 Percent Sodium 26 33 21 30
23 Cyanide (as CN), mg/l BDL BDL BDL BDL
24 Chloride (as Cl), mg/l 290 286 104 464
25 Fluoride (as F), mg/l 0.3 1.0 Nil 1.2
26 Sulphate (as SO4), mg/l 136 155.06 4 160.8
27 Pesticides Nil Nil Nil Nil
28 Total Coliform Organisms,
(MPN/100ml)
6 8 5 18
29 Phenolic Compounds (as C6
H5 OH), mg/l
Nil Nil Nil Nil
Pre-Feasibility Report GCPL – Unit III
66
10.4 Soil Environment
A total of 4-samples was collected in and around the plant site. Samples were collected
using augers at depths upto 30, 60 and 100 cms. The Soil Samples were analysed for pH,
electrical conductivity, nitrogen, phosphorus, potassium, available magnesium,
natural moisture content, grain size distribution (gravel, sand, clay/silt) textural
class, bulk density, plastic limit, liquid limit etc. The undisturbed sample at 60 cm
depth was analysed for field capacity, wilting coefficient, and available water storage
capacity. The results are given in the following Table.
Locations of Soil Sampling Stations
S. No. Code Sampling Station Direction to
proposed project
site
Distance from
proposed project
site (km)
1 SS1 Existing Plant - -
2 SS2 Santanapura Agraharam N 2.0
3 SS3 TVS Nagar SSW 3.5
4 SS4 Sanamavu SE 4.0
Location of the sampling stations are marked in Fig 4.0.
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67
Fig 4.0 Location of Soil Sampling Station
SS1
SS2
SS3
SS4
Pre-Feasibility Report GCPL – Unit III
68
Soil Quality Data
No Location SS1 SS2 SS3 SS4
1. Depth, cm 0-30 30-60 60-100 0-30 30-60 60-100 0-30 30-60 60-100 0-30 30-60 60-100
2. PH 6.5 6.05 6.4 6.7 6.65 6.7 6.8 6.65 6.7 6.8 6.75 6.6
3. Electrical Conductivity ( mho/cm)
10.5 11.1 11.0 12.6 12.9 12.5 13.5 13.0 13.4 11.1 13.3 12.5
4. Moisture Content (%) 5.0 4.5 6.0 4.5 5.1 6.05 3.0 7.5 8.0 10.0 11.5 10.0
5. Organic matter (%) 1.85 1.98 1.5 1.1 1.4 1.25 1.13 1.24 1.2 1.98 2.46 2.38
6. Alkalinity 0.005 0.005 0.005 0.0051 0.0052 0.0051 0.0052 0.0055 0.0051 0.0052 0.0052 0.0053
7. Acidity Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil Nil
8. Sodium Absorption Ratio 0.11 0.1 0.1 0.1 0.09 0.1 0.13 0.11 0.11 0.08 0.090 0.08
9. Nitrogen (as N, %) 0.004 0.004 0.005 0.001 0.001 0.001 0.003 0.004 0.004 0.005 0.003 0.003
10. Phosphorus (as P, %) 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001 0.001
11. Potassium (as K, %) 0.01 0.008 0.01 0.007 0.006 0.006 0.009 0.01 0.001 0.009 0.01 0.008
12. Iron (as Fe, %) 0.8 0.84 0.75 0.55 0.6 0.55 0.51 0.55 0.5 1.07 1.0 1.05
13. Copper (as Cu, %) 0.003 0.003 0.002 0.001 0.001 0.001 0.002 0.002 0.002 0.003 0.003 0.003
14. Zinc (as Zn, %) 0.01 0.01 0.01 0.004 0.003 0.001 0.005 0.005 0.005 0.010 0.005 0.005
15. Manganese (as Mn, %) 0.02 0.02 0.02 0.009 0.009 0.01 0.02 0.02 0.02 0.020 0.02 0.02
16. Boron (as B, ppm) 0.2 0.2 0.22 0.2 0.24 0.21 0.25 0.2 0.21 0.22 0.24 0.21
17. Sodium chloride (as Nacl, %) 0.013 0.016 0.013 0.009 0.008 0.008 0.01 0.01 0.01 0.060 0.04 0.05
18. Sodium Carbonate (as
Na2CO3,%)
0.006 0.004 0.004 0.01 0.01 0.009 0.009 0.01 0.01 0.01 0.01 0.01
19. Texture Sandy Sandy Sandy Sandy Sandy Sandy Sandy Sand Sandy Sandy Sandy Sandy
20. Sand, % 89.45 89.05 89.2 90.4 90.15 90.05 84.4 84.95 84.25 88.55 88.1 87.9
21. Silt & Clay, % 10.5 10.85 10.75 9.55 9.8 9.95 15.6 15.05 15.7 11.45 11.8 12.05
22. Specific gravity, g/cc 2.37 2.38 2.39 2.55 2.5 2.48 2.45 2.5 2.52 2.5 2.53 2.48
23. Bulk Density, g/cc 1.09 1.0 1.03 1.16 1.14 1.1 1.09 1.15 1.14 1.09 1.09 1.13
24. Infiltration Capacity (in cm/hr) 5.0 3.1 2.5 5.5 1.9 1.2 5.8 2.05 1.7 5.4 1.8 1.05
25. Arsenic as As (mg/kg) BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL
26. Cadmium as Cd (mg/kg) BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL
27. Chromium as Cr (mg/kg) BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL
28. Lead as Pb (mg/kg) BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL
29. Mercury as Hg (mg/kg) BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL
Pre-Feasibility Report GCPL – Unit III
69
11.0 WASTE & WASTE MANAGEMENT
11.1 Air Pollution
The major sources of air emissions are from fuel burning in the Boiler in the existing
operation, and Volatile Organic Compounds (VOC) from the proposed operation.
Emissions from combustion of fuels
The emissions are from Diesel Generator & Wood fired boiler.
The Diesel Generator is used only when there is an electrical supply breakdown.
The Wood fired boiler capacity is of 3 T. The stack is to a height of 30 m as per the norms.
It will be ensured that the fuel used will have low sulphur, optimum air fuel ratio to limit
NOx emission. Moreover, the fuel used is wooden briquette, which is most environment
friendly.
Emissions from production process
The emissions from proposed production process are mainly from the reactor and solvent
storage area. The reactors and solvent storage area are proposed to be provided with
adequate measures as fallows.
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 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.
Pre-Feasibility Report GCPL – Unit III
70
11.2 Wastewater Generation
Description Quantity (m³/day)
Existing Proposed
Additional
Upon
Expansion
Process / Floor Wash / Equipment Cleaning 34.0 24.5 58.5
Cooling Water / Boiler Blowdown 4.5 6.5 11.0
Domestic Sewage 4.0 4.8 8.8
TOTAL 42.5 35.8 78.3
11.2.1 Wastewater Management
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.
Pre-Feasibility Report GCPL – Unit III
71
11.3 Solid Wastes
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
Hazardous wastes from the production process are collected and stored in closed containers.
The containers containing the Hazardous waste is stored in a closed shed. The Hazardous
waste is disposed to common waste collection yard of Tamil Nadu Waste Management
Limited at Gummidipoondi, Tiruvallur District.
Sewage Sludge / Sludge from Effluent Treatment
The sewage is connected to SIPCOT sewage system and hence no sewage sludge is
collected within the premises.
The sludge from the effluent treatment is dried in Filter Press. The dried sludge is packed in
polythene woven / polythene bags and the sludge bags are stored in a closed shed. The
hazardous sludge will be disposed to common waste collection yard of Tamil Nadu Waste
Management Limited at Gummidipoondi, Tiruvallur District.
12.0 CONCLUSION
The proposed expansion is planned within the existing premises of GCPL-Unit III located
at # 19, 19B SIPCOT Industrial Complex, Hosur – 635 126, Tamil Nadu, which is a notified
industrial estate in Tamil Nadu. More-over the plant with modern process and techniques
including efficient environment management plan viz., air pollution control system to limit
air emissions, treatment of effluent in a full-fledged ETP / 3 stage RO and disposal of solid
waste in common landfill as authorized will all result in insignificant impact on the ambient
environment.