OF VENSAR LABORATORIES PVT....

ENVIRONMENT IMPACT ASSESSMENT REPORT

& ENVIRONMENT MANAGEMENT PLAN

OF VENSAR LABORATORIES PVT. LTD.

FOR

PROPOSED BULK DRUG & INTERMEDIATES

MANUFACTURING UNIT

AT

SY.No:32, TUPAKULAGUDEM (V), TALLAPUDI (M), WESTGODAVARI (DIST.) ANDHRA PRADESH

PREPARED BY:

Rightsource Industrial Solutions Pvt. Ltd Plot No: 203, H. No: 5-36/203, Prashanthi Nagar, IDA, Kukatpally, Hyderabad – 500072. Ph: 040-23070602, 23075699, 40126589. Email: [email protected].

UNDERTAKING BY PROJECT AUTHORITIES

COPY OF

TERMS OF REFERENCE [TOR]

TOR COMPLIANCE

TOR Compliance of EIA Report Vensar Laboratories Pvt. Ltd

Prepared By Rightsource Industrial Solutions Pvt. Ltd Page 1

TOR COMPLIANCE S. No TOR Point Chapters Page No

1 Executive summary of the project Attached with EIA report 2 Justification of the project Chapter - I 4 3 Promoters and their back ground Chapter - I 2

4 Regulatory framework Chapter - I 6

5 A Map indicating location of the project and distance from severely polluted area. Not Applicable

6 Project location and plant layout Chapter - II 2

7 Infrastructure facilities including power sources. Chapter - II 7-8

8 Total cost of the project along with total capital cost and recurring cost/annum for environmental pollution control measures.

Chapter - X 52-53

9 Project site location along with site map of 10 km area and site details providing various industries, surface water bodies, forests etc.

Chapter - II 6

10 Present land use based on satellite imagery for the study area of 10 KMs radius Details of land availability for the project along with supporting document.

Chapter - III 41

11 Location of National Park/Wild life sanctuary/Reserve forest within 10 km radius of the project. Chapter - II 6

12 Permission from the State Forest Department regarding the impact of the proposed plant on the surrounding reserve forests / Defence area.

No impact of the proposed plant on the surrounding

Reserve Forests / Defence Area.

13 Details of the total land and break-up of the land use for green belt and other uses. Chapter -II 7-8

14 List of products along with the production capacities Chapter -II 9

15 Detailed list of raw material required and source, mode of storage. Chapter -II 52-54

16 Manufacturing process details along with the chemical reactions and process flow chart Chapter - II 10-44

17 Action plan for the transportation of raw material and product. Chapter - X 7

18 Site –specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall is necessary.

Chapter - III 6-8

19

Ambient air quality monitoring at 6 locations within the study area of 5 KMs. aerial coverage from project site as per NAAQES notified on 16th September, 2009 Location of one AAQMS in downwind direction.

Chapter - III 13-19

20 One season site –specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall and AAQ data (except monsoon)

Chapter - III 13-19



for PM2.5, PM10, SO2, NOx, CO, NH3 including VOCs shall be collected. The monitoring stations shall take into account the pre-dominant wind direction, population zone and sensitive receptors including reserved forests. Data for water and noise monitoring shall also be included.

21 Details of water and air pollution and its mitigation plan Chapter - IV 18-19

22 Air pollution control measures proposed for the effective control of gaseous/process emissions within permissible limits.

Chapter - II 52

23 An action plan prepared by SPCB to control and monitor secondary fugitive emissions from all the sources.

Chapter -II Chapter - X

51 42-43

24

Determination of atmospheric inversion level at the project site and assessment of ground level concentration of pollutants from the stack emission based on site specific meteorological features. Air quality modeling for proposed plant.

Chapter - IV 10

25 Name of all the solvents to be used in the process and details of solvent recovery system. Chapter - II 52

26 Design details of ETP , incinerator, if any along with boiler, scrubbers/bag filters etc.

Chapter - II Chapter - X

49-50 8-24

27 Action plan to control ambient air quality as per NAAQS Standards notified by the Ministry on 16th September, 2009.

Chapter - X 6

28

Source and permission from competent Authority for the drawl of water. water balance chart including quantity of effluent generated recycled and reused and effluent discharge

We will submit

Chapter -II chart : Chapter- X, page nos: 8-24

29 Complete scheme of effluent treatment characteristics of untreated and treated effluent to meet the standard. Chapter- II 47

30 Zero discharge effluent concepts to be adopted. Chapter - X 8-24

31

Ground water quality monitoring minimum at 6 locations shall be carried out Geological features and Geo-hydrological status of the stud area and ecological status (Terrestrial and Aquatic)

Chapter - III 35

32

The details of solid and hazardous wastes generation, storage, utilization and disposal particularly related to the hazardous waste calorific value of hazardous waste and detailed characteristic of the hazardous waste. Action plan for the disposal of fly ash generated from boiler shall be included

Chapter - II Chapter - X

47 48-49

33 Material Safety data sheet for all the chemicals are being used/will be used.

MSDF for all the chemicals are will be used and kept in plant

for reference.

34 Authorization / Membership for the disposal of solid /hazardous waste in TSDF. We will submit

35 Risk assessment for storage for chemicals / solvents. Action plan for handling & safety system Chapter - VII 3-21

36 An action plan to develop green belt in 33 % area. Layout plan for green belt shall be provided. Chapter - X 32-34



37 Action plan for rainwater harvesting measures at plant site shall be included to harvest rainwater from the roof tops and storm water drains to recharge the ground water.

Chapter - X 50-51

38

Details of occupational health programme a. To which chemicals, workers are exposed directly

or indirectly b. Whether these chemicals are within Threshould

Limit values (TLV)/ Permissible Exposure Levels as per ACGIH recommendation.

c. What measures company has taken to keep these chemicals within PEL/TLV.

d. How the workers are evaluated concerning their exposure to chemicals during pre-placement and periodical medical monitoring

e. What are onsite and offisite emergency plan during chemical disaster

f. Liver function tests (LFT)during pre-placement and periodical examination

g. Details of occupational health surveillance programme.

Chapter - VII Chapter -X

26-31 53-54

39 Socio-economic development activities shall be in place Chapter - III 49

40

At least 5 % of the total cost of the project should be earmarked towards the Enterprise Social Commitment based on Public Hearing issues and item –wise details along with time bound action plan should be prepared and incorporated.

Chapter - VIII 2-4

41 Note on compliance to the recommendations mentioned in the CREP guidelines Chapter -X 57-59

42

Detailed Environment management Plan (EMP) with specific reference to details of air pollution control system, water & wastewater management, monitoring frequency, responsibility and time bound implementation plan for mitigation measure shall be provided.

Chapter - X Chapter -IV

3-8 4-5

43 EMP shall include the concept of waste-minimization, recycle / reuse / recover techniques, Energy conservation, and natural resource conservation.

Chapter - X 56

44 Total capital cost and recurring cost/annum for environmental pollution control measures Chapter - X 52-53

45

Corporate Environmental Responsibility a. Does the company have a well laid down

Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report

b. Does the Environmental policy prescribes for standard operating process/procedures to bring into focus any infringement/ deviation / violation of the environmental or forest norms /conditions? If so, it may be detailed in the EIA report.

c. What is the hierarchical system or Administrative order of the company to deal with the environmental issues and for ensuring compliance

Chapter - VI 6-8



with the EC conditions. Details of the system may be given.

d. Does the company have a system of reporting of non-compliance / violation of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism should be detailed in the EIA report.

46 Any litigation pending against the project and /or any direction /order passed by any court of law against the project, if so, details thereof.

There is no litigation pending against the project

ADDITIONAL TOR

1

Public hearing to be conducted and issues raised ,commitment made by the project proponent and the same should be included in EIA /EMP report in the form of tabular chart with financial budget for complying with the commitments made The following general points shall be noted: i. All documents shall be properly indexed, page numbered. ii. Period/date of data collection shall be clearly indicated. iii. Authenticated English translation of all material in Regional languages shall be provided iv. The letter/application for environmental clearance shall quote the MOEF file No. and also attach a copy of the letter. v. The copy of the letter received from the Ministry shall be also attached as an annexure to the final EIA-EMP Report. vi. The index of the final EIA-EMP report must indicate the specific chapter and page no. of the EIA-EMP Report

Noted

EIA&EMP report was properly indexed, page numbered. Clearly indicated period & date

Noted

Attached

Noted

EIA-EMP report clearly indicated the specific chapter

and page nos

Noted and followed



2

These TORs should be considered for the preparation of EIA/EMP for synthetic organic manufacturing unit at Sy no. 32, Tupakulagudem (V), Tallapudi (M), West Godavari (DT), Andhra Pradesh by Vensar Laboratories Pvt Ltd. in addition to all the relevant information as per the ‘General Structure of EIA’ given in appendix III and IIIA in the EIA notification , 2006. The EIA/EMP as per TORs should be submitted to the chairman, Telangana Pollution Control Board, for public consultation. The SPCB shall conduct te public hearing. Public consultation as per the provisions of EIA notification, 2006.

3

You are requested to kindly submit the final EIA/EMP prepared as per TORs and incorporating all the issues rose during Public Hearing/ Public Consultation to the Ministry for considering the proposal for Environmental Clearance within 3 years as per the MoEF O.M. No.J-11013/41/2006-IA.II (I) dated 8th October, 2014.

4

The consultants involved in the preparation of EIA/EMP report after accreditation with Quality Council of India/ National Accreditation Board of Education and Training (QCI/NABET) would need to include a certificate in this regard in the EIA/EMP reports prepared by them and data provided by other Organizations / Laboratories including their status of approvals etc.,

LIST OF CONTENTS [INDEX]

EIA Report Vensar Laboratories Pvt. Ltd


LIST OF CONTENTS

CHAPTER - I INTRODUCTION

S. No Description Page No

1.1 Identification of project & Project proponent 1 1.1.1 Identification of Project 1 1.1.2 About the Promoters 2 1.2 Purpose of the Report 3 1.3 Objective and Scope of the Study 3

1.3.1 Objective 3 1.3.2 Scope of Study 4

1.3.2.1 Environmental Impact Assessment 4 1.3.2.2 Socio-Economic Assessment 4 1.3.2.3 Regulatory Scoping 4 1.3.2.4 Justification of the Project 4

1.4 Project location and compliance of site with selection criteria

5

1.5 Regulatory Framework 6 1.6 Legal Policy and Institutional Frameworks 6

CHA PTER - II PROJECT DESCRIPTION

S. No Description Page No 2.1 Type of the project 1 2.2 Location 1 2.3 Proposed schedule for approval and implementation 1 2.4 Infrastructure / Site plan Details 7 2.5 Process Description 9

2.5.1 Manufacturing process, details with flow charts & material balance

10-44

2.6 Pollution Load 45

2.6.1 Proposed Water Consumption Details & Waste water Generation details

46

2.6.2 Waste water characteristics 47 2.6.3 Hazardous & Solid waste generation details 47 2.7 Power(Energy) requirement 48 2.8 Utilities 48

2.9 Proposed boilers, DG sets & Stack emission details of existing thermo pack boiler

49

2.10 Details of Solvent Input, Recovery & Loss Product Wise

51

2.11 Details of Process Emission 52 2.12 List of Raw Materials product wise 52-54



CHAPTER - III DESCRIPTION OF THE ENVIRONMENT


3.0 Introduction 1 3.1 Study Area 1 3.2 Study Period 1 3. 3 Geology and Hydro geological Environment 2

3.3.1 Topography 3 3.3.2 Geology 3 3.3.3 Hydrogeology 3 3.3.4 Micrometeorology and Climate 6-8 3.4 Air Environment 10-11

3.4.1 National Ambient Air Quality Standards (NAAQS) 13 3.4.2 Ambient Air Quality Data (AAQ) 14-19 3.5 Water Environment 19

3.5.1 Methodology For Water Quality Monitoring 20 3.6 Noise Environment 27

3.6.1 Noise Monitoring Stations 28 3.6.2 Traffic Study 30 3.7 Soil Environment 33 3.8 Land Use Pattern 36

3.8.1 Data Used 36 3.8.2 Land use / Land Cover Map 37

3.8.2.1 Basic concepts of land use 38 3.8.2.2 Methodology for land use / land cover mapping 38

3.9 Ecological Environment 44-46 3.9.1 Terrestrial fauna of the Core area and the Buffer zone 46-48 3.9.2 Aquatic flora and fauna 48 3.10 Socio Economic environment 49

3.10.1 Methodology Adopted for the Study 49 3.10.2 Distribution of Population in the study area 49 3.10.3 Literacy & Illiteracy Rate 51 3.10.4 Occupational Structure 52 3.10.5 Civic Amenities Available In The Study Area 53-55 3.10.6 Corporate Social Responsibility of the Project Proponent 55

CHAPTER - IV ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES


4.1 Introduction 1 4.2 Prediction Of Impacts During Construction Phase 1

4.2.1 Impact On Land Use 1 4.2.2 Impact On Land / Soil Environment 2 4.2.3 Impact On Topography 2 4.2.4 Impact On Air Quality 2




4.2.5 Impact On Water Quality 3 4.2.6 Impact On Noise Levels 3 4.2.7 Impact On Ecology 3 4.2.8 Impact On Socio-Economic Environment 4 4.3 Mitigation Measures During Construction Phase 4

4.3.1 Land/Soil Environment Management 4 4.3.2 Air Quality Management 4 4.3.3 Water Quality Management 5 4.3.4 Noise Level Management 5 4.3.5 Ecological Management 5 4.3.6 Social Community Management 5 4.4 Prediction Of Impacts During Operational Phase 5 4.5 Air Environment 6

4.5.1 Source Of Air Pollution 6-7 4.5.2 Prediction of Impacts on Air Environment 8-12 4.6 Water Environment 14 4.7 Noise Environment 15 4.8 Impact on Land Use 15 4.9 Soil conservation 15

4.10 Impact of Solid Waste 16 4.11 Impacts on Ecology 17 4.12 Impacts on Socio- Economy 18 4.13 Impacts on Hydrology and Geology 18 4.14 Mitigation Measures During Operational Phase 18

4.14.1 Mitigation Measures For Air Environment 18 4.14.2 Mitigation Measures For Water Environment 19 4.14.3 Measures For Hazardous/Solid Waste 19 4.14.4 Measures For Noise 20 4.14.5 Measures for soil conservation 20 4.14.6 Measures for land use 20 4.14.7 Ecology and Biodiversity 21 4.14.8 Health & Safety Measures 21 4.15 Odour control measures 22

4.15.1 Handling 22 4.15.2 Transportation of raw materials 22 4.15.3 Other sources of odour nuisance 23 4.15.4 Control measures 23 4.15.5 Cleaner production practices 23-24

CHAPTER - V ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE)

S. No Description Page No 5.1 Introduction 1



CHAPTER - VI ENVIRONMENTAL MONITORING PROGRAM


6.1 preamble 1 6.2 Monitoring program 1 6.3 Infrastructural requirement & procurement

schedules 2

6.3.1 List of instrumental for environmental monitoring 3-4 6.4 Corporate environmental responsibility 4-5 6.5 Environmental Management Cell 6-8 6.6 Administrative actions & Documentation 8

6.6.1 Data analysis 8 6.6.2 Reporting schedules 8 6.6.3 Environmental monitoring expenditure 8

CHAPTER -VII ADDITIONAL STUDIES, RISK ASSESSMENT & DISASTER MANAGEMENT REPORT

S. No Description Page No 7.1. Introduction 2 7.2. Identification of hazards 2 7.3 Safe practice [Handling ,Storage, Transportation,

and unloading of chemicals 20

7.4 Safety instructions for transportation of hazardous materials

21

7.5 Spill control 22 7.6 Identification of High Risk areas 22

7.7.1 Modes of Failure 22 7.7.2 Maximum credible accident analysis and

mitigation measures 23

7.7.3 Consequence analysis 24 7.7.4 Possible Accident Scenario 24-26 7.8 Occupational Health 26-31 7.9 Treatment of workers affected by Accidental

spillage of Chemicals 32-33

7.10 Safe Operating Procedures 33 7.11 Fire Protection 34 7.12 Static Electricity 34 7.13 Communication system 34 7.14 Safety inspections 34 7.15 Predictive and Preventive maintenance 34 7.16 Electrical safety 35 7.17 Colour coding system 35 7.18 Disaster Management Plan 35

7.18.1 Structure of emergency management system 35 7.18.2 Emergency management system - Roles &

Responsibilities 36-38



CHAPTER - VIII PROJECT BENFITS


8.1 Employment opportunity 1 8.2 Corporate social responsibility (CSR) &

socioeconomic development 1-5

8.3 Direct revenue earning to the national and state exchequer

5

8.4 Infrastructural benefit 5 8.5 Other Tangible Benefits 5-6

CHAPTER - IX ENVIRONMENTAL COST BENEFIT ANALYSIS


9.1 Cost benefit analysis 1

CHAPTER - X ENVIRONMENTAL MANAGEMENT PLAN

S. No Description Page No 10.1 Introduction 1 10.2 Pre-Project Environmental Management Plan 3

10.2.1 Site Preparation 3 10.2.2 Sanitation 3 10.2.3 Noise 3 10.2.4 Construction Equipment And Waste 3

7.18.3 Other Elements of DMP 39 7.18.4 Fire services 40 7.18.5 Medical Services 41 7. 18.6 Security services 41 7.18.7 Mutual AID 42 7.18.8 Emergency Response 43 7.18.9 Emergency Capabilities 43

7.18.10 Emergency Handling procedures 43 7.18.11 Mitigation of Environmental impact during Fire

Emergency 45

7.18.12 Raising the Alarm 46 7.18.13 Declaring Major Emergency 7.18.14 Transportation and Evacuation arrangements 46 7.18.15 Plant operations 47 7.18.16 Telephone Messages 47 7.18.17 Mock Drill 47

7.19 Offsite Emergency plan 49



10.2.5 Site Security 3 10.3 Environmental Management During Operation 4

10.3.1 Air Quality 4 10.3.1.1 Air Pollution Control / Management 4

A Stack Design 4 B Expected process Emission Control 4 C Action plan to control Ambient Air Quality as per NAAQS

Standards 6

D Fugitive Emission from Solvents 7 E Storage and Transportation of Raw Materials 7 F Storage and Transportation of Solvents 7

10.3.2 Noise Pollution 8 10.3.3 Water Quality 8

10.3.3.1 Details of ZLD system 13 10.3.3.2 The technical details of the systems are as follows 14 10.3.3.3 MEE plant configuration 14 10.3.3.4 Process description (Part - A) 14 10.3.3.5 Process description (Part - B) 15 10.3.3.6 Process description (Part - C) 16 10.3.3.7 Material of construction 17 10.3.3.8 Details of 20 KLD MEE system 18-19 10.3.3.9 ETP With 20 KLD RO Plant Configuration 21-24

10.4 Hazardous/ Solid Waste Management 25-26 10.5 EB [Ecology & Biodiversity 27 10.6 SE [Socio-Economic Aspects 28 10.7 HG [Hydrogeology, Ground Water & Water Conservation] 28 10.8 GEO [Geology] 29 10.9 SC [Soil Conservation] 30

10.10 RH [Risk & Hazards Management] 30-32 10.11 Greenbelt Development 32

10.11.1 Objective 32-34 10.12 Post Project Monitoring 34

10.12.1 Air Pollution Monitoring 35 10.12.2 Waste Water Monitoring 35 10.12.3 Ground Water Monitoring 35 10.12.4 Hazardous / Solid Waste Monitoring 35 10.13 Management Of Public Interests 36

10.13.1 Objective 36 10.13.2 Preference To Local Population 37 10.13.3 Health Camps 37 10.13.4 Public Amenities 37 10.13.5 Public Relations 37 10.14. Environmental Management 37 10.15 Project Details 38 10.16. Process Plant And Machinery 38 10.17 Auxiliary Plants 38 10.18 Resources Available With The Project 38



10.18.1 Land Area 38 10.18.2 Water Requirement 39 10.18.3 Raw Material Requirement 40 10.18.4 Power Requirement 40 10.19 Process Details 40

10.19.1 Process Description And Material Balance 40 10.20 Pollution Loads 41

10.20.1 Air Pollution Loads - Expected Process Emissions 41 10.20.2 Process Emission Control System 42 10.20.3 Fugitive Emissions 42 10.20.4 Emissions – Utilities 45-47 10.20.5 Stage wise Effluent Characteristics 48 10.21 Hazardous & Solid Waste details 49

10.21.1 Hazardous & Solid waste characteristics 50 10.22 Roof Water Harvesting 51 10.23 Investment 52

10.23.1 Budget allocation 53 10.24 Occupational safety and Health aspects 53-54 10.25 Socio-Economic development activities 54-55 10.26 Waste Minimization / Resource Conservation

5 r concept (Recycle / Refuse / Reduce / Reuse / Reform) 56

10.27 CREP Action Points For Pharmaceutical Industries 57-59 10.28 Conclusion 59

CHAPTER - XI SUMMARY & CONCLUSION (THIS WILL CONSTITUETE THE SUMMARY OF THE EIA REPORT)


11.1 Salient features of the project 1-2 11.2 conclusions 2

CHAPTER -XII DISCLOSURE OF CONSULTANTS ENGAGED


12.1 Accreditation certificate of the company 1 12.2 RISPL signatory sheet 2



LIST OF TABLES

CHAPTER - I INTRODUCTION

Table No

Description Page No

1.1 Project location and Compliance of site 5

1.2 Applicability of legal policies to the project 6-8

CHAPTER - II PROJECT DESCRIPTION

Table No

Description Page No

2.1 Land use details 7 2.2 List of proposed products and Capacities 9 2.3 List of By- Products and quantities 9 2.4 Consolidated pollution load of all products in Kgs

per day 45

2.5 Proposed water consumption details 46 2.6 Proposed effluent generation details 46 2.7 Proposed HTD & LTD effluent details 47 2.8 Proposed Hazardous Waste & Solid Waste

Generation, Disposal Details 48

2.9 Details of Proposed Utilities 48 2.10 Emission Characteristic Details Boilers 49 2.11 Stack Emission Details of DG Sets 49 2.12 Stack Emissions Details of Thermopack Boilers 50 2.13 Details of Proposed Solvent Input, Recovery &

Loss [Product Wise] 51

2.14 Expected Process Emission Details 52


Table No

Description Page No

3.1 Frequency distribution wind directions and wind speed 8

3.2 Ambient air quality sampling locations 11 3.3 National ambient air quality standards 13-14

3.4 The maximum ,minimum & 98th percentile values for all the sampling locations 16

3.5 Ambient air quality, station : Project Site A1 17 3.6 Ambient air quality station : A2(Gopavaram) 17 3.7 Ambient air quality station : A3(Ramapalem) 18 3.8 Ambient air quality station : A4(Bhimolu) 18 3.9 Ambient air quality station : A5(Surayyapeta) 19



3.10 Ambient air quality station : A6 ( Tupakulagudem) 19 3.11 Ground water and Surface sampling locations 21 3.12 Ground water quality in the study area 24-25 3.13 Surface water quality the study area 26 3.14 Noise monitoring locations 28 3.15 Ambient noise levels within study area 29

3.16 Traffic Study at SH-42 (Chityala to Tallapudi road) 32

3.17 Soil sampling location 33 3.18 Soil sampling analysis result 35

3.19 Showing the Details of Sources & the Maps Prepared 36

3.20 Showing the Topographic Maps 36 3.21 Satellite Data of National Remote Sensing Center 37

3.22 Land Use / Land Cover Statistics of the Study Area 43

3.23 List of trees Found in the Core Area & Buffer area 45

3.24 List of Shrubs & Herbs found in the Core area & Buffer Zone 46

3.25 List of Vertebrates other than Birds observed in the study area 47-48

3.26 List of Birds Either Spotted or Reported From The Areas in and around the Project Site 48

3.27 The Demographic Details 50

3.28 Distribution of Literacy Rate and Illiteracy Rate in the Study Area 51

3.29 Occupational Structure In Study Area 52 CHAPTER - IV ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

Table No

Description Page No

4.1 Emission details from proposed boilers after expansion 6

4.2 Emission Details from DG Set Stack After Expansion 7 4.3 Predicted 24- hourly short term incremental

concentrations 10

4.4 Resultant concentration due to incremental GLC’s 10 4.5 Total Water requirement 14 4.6 Total Waste Water Generation 14 4.7 Solid & Hazardous Waste Generation and Disposal

Mode 16



CHAPTER - VI ENVIRONMENTAL MONITORING PROGRAM Table

No Description Page

No 6.1 The details of the monitoring program 1-2 6.2 Corporate environmental responsibility 5 6.3 Responsibilities of EMC 7-8

CHAPTER -VII ADDITIONAL STUDIES, RISK ASSESSMENT & DISASTER MANAGEMENT REPORT

Table No Description Page

No

7.1 Details Of Storage Of Raw / Hazardous Materials And Control Measures 4-15

7.2 Raw materials Inventory 17-18 7.3 List of Finished Products 18 7.4 Storage Details of Solvents 24 7.5 Solvent/ Chemical Exposure Limits 29


Table No

Description Page No

10.1 Proposed Hazardous / Solid waste generation and Disposal

26

10.2 List of Plants for Green Belt 34 10.3 The details of the Monitoring Program 35-36 10.4 List of Proposed Product With Therapeutic Category

after expansion 37

10.5 Land use details of plant site 39 10.6 Water consumption details 39 10.7 Water Consumption-Product Wise in process-product

wise 40

10.8 Process Emission Details 41 10.9 Process Emission Details –product wise 41

10.10 Fugitive/solvent Emissions Details Product Wise 44 10.11 Emission characteristics Details of proposed Boiler 45 10.12 Stack emissions details of proposed Thermopack boiler 45 10.13 Stack Emission Details of proposed DG sets 46 10.14 Proposed effluent generation details 46 10.15 Proposed HTDs & LTDs effluent details 48 10.16 Waste water generation kg per day -product wise 48 10.17 Hazardous / Solid waste generation, disposal Details 49 10.18 Hazardous / Solid waste generation after expansion-

product wise per day 49

10.19 Available rain water (annual)for harvesting 51 10.20 Budgets for Environmental Management plan 52



LIST OF FIGURES

CHAPTER - II PROJECT DESCRIPTION

Figure No

Description Page No

2.1 Location map 2 2.2 Google Earth Map Showing Route map of

Project Site location 3

2.3 Google Earth Map Showing Project Site 4 2.4 Latest photographs of plant site 5 2.5 Topo map showing 10 KMs radius 6 2.6 Infrastructure / Site plan details 8


Figure No

Description Page No

3.1 Showing Drainage Map of The Study Area 5 3.2 Windrose diagram 9 3.3 Ambient air quality sampling location map 12 3.4 Ground & surface water sampling location map 22 3.5 Noise sampling location map 29 3.6 Soil sampling location map 34 3.7 Satellite image of the study period 41 3.8 Land use /Land cover of the study area 42 3.9 Pie diagram of land use in the study area 43

3.10 Diagram Showing Total Population Distribution in the Study Area

51

3.11 The Diagram Showing Literates and Illiterates in Study Area

52

3.12 The Diagram Showing Occupational Structure in Study Area

53

CHAPTER - IV ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

Figure No Description Page

No 4.1 Short term 24 hourly incremental GLCs of SPM 11 4.2 Short term 24 hourly incremental GLCs of SO2 12 4.3 Short term 24 hourly incremental GLCs of NOx 13



CHAPTER - VI ENVIRONMENTAL MONITORING PROGRAM


No 6.1 Environmental management cell 6



No 10.1 Flow chart of EMP 2

10.2 Schematic diagram of waste water treatment 10 10.3 Flow chart for effluent treatment HTDS 11 10.4 Flow chart for effluent treatment LTDS 12 10.5 Flow chart for Effluent Treatment 13 10.6 Schematic diagram of MEE system 21 10.7 Schematic diagram Emissions Control System 42 10.8 Roof water harvesting pit 52 10.9 5 R concept 56

LIST OF ENCLOSURES

S. No Description Enclosure No

1 Consolidated– Pollution Load Details Enclosure – 1 2 News Paper Advertisement (Public

Hearing) Enclosure – 2

3 Minutes of the Meeting(Public Hearing) Enclosure – 3 4 SPCB present status certificate submission

acknowledgement Enclosure –4

EXECUTIVE SUMMARY OF EIA REPORT

EXECUTIVE SUMMARY OF

EIA REPORT

OF

VENSAR LABORATORIES PVT LTD. SY.No:32, TUPAKULAGUDEM (V),

TALLAPUDI (M), WEST GODAVARI (DIST.) ANDHRA PRADESH

For

Proposed Bulk Drug & Intermediates Manufacturing Unit

PREPARED BY

Rightsource Industrial Solutions Pvt. Ltd Plot No: 203, H.No:5-36/203, Prashanthi Nagar,

IDA, Kukatpally, Hyderabad – 500072. Ph: 040-65873137, 23070602, 23075699, 40126589. Fax: 040-23070602. Mail: [email protected]

Executive Summary of EIA Report Vensar Laboratories Pvt. Ltd.

Prepared By Rightsource Industrial Solutions Pvt. Ltd. Page 1

1. INTRODUCTION Vensar Laboratories Pvt Ltd proposes to establish a Bulk Drug & Intermediates

manufacturing unit at Survey No: 32, Tupakulagudem (V) Tallapudi (M), West

Godavari (Dist.), Andhra Pradesh.

The industry proposes to establish unit in an area of 7.00 Acres (28328.00 SQM).

The Industry is having its administrative office at Duplex No:12,

Lakshmi Gayatri Enclave, Aditya Nagar, KPHB, Kukatpally, Hyderabad.

The proposed project cost is about Rs.6.00 Crores, which includes construction of

the buildings, equipment, machinery and greenbelt development.

The proposed Project is to obtain Environmental Clearance from the Ministry of

Environment, Forests & Climate Change (MoEF&CC) and Consent Orders from

SPCB to manufacture proposed products (given in Table-2) with a total production

capacity of 10 MT/Month. EIA report is prepared considering the Terms of

Reference (ToR) & its amendments issued by MoEF&CC vide F. No. J-

11011/368/2014 - IA II (I) Dated 10th March 2015 & 8th September 2016. As per

Issued TOR - EIA Study was carried out with necessary Environmental studies &

Monitoring during one Month period of March 2016.

1.1. PROJECT DESCRIPTION The salient features of the unit are furnished below.

TABLE-1: SALIENT FEATURES OF THE PROJECT

Particulars Details Name of the project Vensar Laboratories Pvt Ltd

Location of the project Survey No: 32, Tupakulagudem (V) Tallapudi (M), West Godavari (Dist.), Andhra Pradesh.

Latitude & Longitude Latitude: 17009’27.76” North Longitude: 81035’32.23” East.

Land acquired for the plant 7.00 Acres (28328.00SQM) Present Land use of the project site Private Land

Nearest village Gopavaram Village – 1.43 KMs (NNE) Nearest Town Kovvur- 20 KMs (SE)

Major Cities Rajahmundry - 24 KMs (SE) Eluru - 69 KMs (S)

Nearest National High way Nearest State High way

National Highway No: 5 -26 KMs (SE) (Rajahmundry – Anakapalle) State Highway No: (SH-42) - 17 KMs (W) (Koyyalagudem - Nallajerla)



Particulars Details Nearest Railway station Nearest Airport

Kovvur Railway station – 22.0 KMs (SE) Rajahmundry Airport (Madhurapudi)– 24.00 KMs (ESE)

Major Industries near the plant site Andhra Sugars Limited (Chemicals & Fertilizers Limited)

Reserve Forests with in 10 KMs Radius

Fairly dense jangle near Gopavaram - 1.2(WNW) Dense Mixed jangle near Hukumpet - 4.8 KMs (NNW) Mixed jangle near Rajampalem - 5.1KMs (NNW)

Vinjaram R.F. -9.1 KMs(NNW) Karakapadu RF – 9.4 KMs (NW)

Polavaram RF- 9.6 (N)

Water Bodies with in 10 KMs Radius

Tadipudi lift canal – 1.50 KMs (S) Tank near Bhimolu – 2.65 KMs (SW) River Godavari– 7.8 KMs (E) Kovada kalva - 6.25 KMs (N) Polavaram Right Canal - 3.5 KMs (WNW) Tank near Ramannapalem – 7.80KMs(N) Pendrala kalva - 8.4 KMs (NW) Kovvada Kalva Reservoir – 9.62 KMs (NW)

2.0 PROCESS DESCRIPTION

The manufacturing process of bulk drugs consists of chemical synthesis extending to

stages of processing involving different type of chemical reactions. Total production

capacity of proposal will be 10.00 MT/Month. (Given in Table - 2). The unit will take

adequate control measures for storage and handling of Raw materials, solvents and

cylinders with in factory premises.

TABLE- 2: PROPOSED PRODUCTS AND QUANTITIES

S. No Product Name CAS Number

Therapeutic category /

Application

Quantity In

Kgs/Month Quantity In

Kgs/Day

1 Carvedilol 72956-09-03 Cardiovascular 5000.00 166.67

2 Citalopram Hydro Bromide 59729-32-7 Antidepressant 2000.00 66.67

3 Ketrolac tromethamine 74103-06-3 Anti-

inflammatory 5000.00 166.67

4 Ramipril 87333-19-5 Cardiovascular 5000.00 166.67

5 Sertraline Hydrochloride 79559-97-0 Antidepressant 5000.00 166.67

6 Terbinafine Hydrochloride 78628-80-5 Antifungal 4000.00 133.33

7 Tramadol Hydrochloride 36282-40-0 Analgesic 5000.00 166.67

Total (Worst combination of any two products on campaign basis only) 10000.00 333.33



TABLE- 3: LIST OF BY- PRODUCTS AND QUANTITIES

S. No Name of the Product

Name of the By-Product

Quantity In Kg/Day

Disposal Option

1 Citalopram hydro bromide Magnesium chloride 32.00 For Sale

2 Ramipril Triethyl amine Hydrochloride 215.00 For Sale

3 Terbinafine Hydrochloride Potassium chloride 31.00 For Sale

2.1 RESOURCE REQUIREMENT & INFRASTRUCTURE FACILITIES A) Land Use Details:

M/s. Vensar Laboratories Pvt. Ltd. proposes to establish in an area of the total

land is 7.00 Acres (28328.00 SQM), the usage details are given table No: 3.

TABLE-4: PROPOSED LAND USE DETAILS

S. No Description Area (SQM)

Area (Acres)

1 Built up land 10764.64 2.66 2 Greenbelt area 9914.8 2.45 3 Roads area 5382.32 1.33

4 Open area/Parking 2266.24 0.56

Total 28328.00 7.00 More than 33 % of land allotted for Greenbelt.

B) Water Consumption

The Total water consumption for the proposed project is 79.71 KLD. Water consumption details are given in below Table. No.4. Water requirement will be met through Ground Water.

TABLE-5: PROPOSED WATER CONSUMPTION DETAILS

S.No Purpose Water consumption In KLD 1 Process 28.21 2 Washings 2.00 3 Boiler make up 26.00 4 Cooling towers make up 15.00 5 Scrubbing system 1.00 6 Domestic 3.50 7 Gardening 4.00

Total 79.71



Out of Total Water consumption of 79.71 KLD an amount of 21.24 KLD of water will be recovered by the ZLD system and reused, Hence, Total fresh water requirement is 58.47 KLD and will be met from Ground Water.

C) Energy Requirement

Power requirement of proposed project will be made available through SPDCL. Total

power requirement of proposed plant shall be 300 KVA.

D) Utilities:

For generation of Steam, the industry proposing a 6.0TPH Coal fired / Agro waste

boiler. The coal requirement will be met from government allocation or from local

authorized sources, and the company is proposing 2,00,000 K. Cal / Hr. Thermo

pack Agro Waste / Coal fired Boiler.

Proposing 250 KVA DG sets for usage during the power failures. The emissions

details are presented in bellow table No: 6, 7, 8 & 9.

TABLE-6: DETAILS OF PROPOSED UTILITIES

S. No Description Capacity

Proposed

1 Coal fired boilers 6.0 TPH Proposed 2 DG Sets 250 KVA Proposed 3 Cooling Towers 1X1000TR Proposed

4 Thermo pack Boiler

2, 00,000 K. Cal / Hr. Proposed

5 Electricity supply from APSPDCL. 300 KVA Proposed

Fuel

1 Indian Coal / Agro waste 15.0TPD

2 Diesel 40 Liters/Day

TABLE-7: EMISSION CHARACTERISTIC DETAILS OF BOILER

Particulars Units 6.0 TPH Coal fired /

Agro waste fired Boiler (Proposed)

Type of Fuel -- Indian Coal/Agro waste Coal Consumption TPD 15.0 Ash Content % 47 Sulphur Content % 0.8 Nitrogen Content % 1.07 No. of Stacks No 1 Height of stack m 32



Diameter of Stack m 0.60 Temperature of Flue Gas

oC 110

Velocity of Flue Gas m/s 8.50 Particulate Matter at outlet of Bag filter (Based on 115 mg/Nm3 at outlet)

gm/sec 0.62

Sulphur dioxide emission gm/sec 1.39

Oxides of Nitrogen emission gm/sec 1.86

Pollution control equipment -

Cyclone separator followed by suitable pack

of Bag filters

TABLE-8: STACK EMISSION DETAILS FOR THERMO PACK BOILER

Particulars Units 2, 00,000 K. Cal/Hr. Thermo pack Boiler

(Proposed) Thermo pack Boiler Capacity

K. Cal / Hr. 2,00,000

Type of Fuel -- Agro waste / Coal Stack Temperature Before Air preheater

oC 250

Stack Temperature After Air preheater

oC 180

Combination Air Temperature

oC 120

Efficiency Increased By % 5 Stack Height m 9.0 Fuel Consumption per Day TPD 2.0 Diameter m 0.5

TABLE-9: STACK EMISSION DETAILS FOR DG SETS

Capacity In KVA

Emission of SPM

in mg/Nm3

Emission Of SO2 in mg/Nm3

Emission of NOx In mg/Nm3

Stack dia. In m

Flue Gas

Temp. in OC

Stack Height in m

Flue gas Velocity

In m/sec.

250 KVA (Proposed)

58.0 24.0 30.0 0.30 250 10 18.24



3. BASELINE ENVIRONMENTAL STATUS

3.1 Study Area Included In Environmental Setting

Studies were carried out in about 10 KMs radius area from the site with respect to

meteorology, flora, fauna, land and socio-economies of the area. Further sampling

and analysis of air quality, water quality, noise level and soil quality were carried out.

The air quality, water quality, noise level and soil quality in the study area is

evaluated based on this physical sampling and analysis.

The base line data were monitored during one month period of March 2016. The

study team conducted site surveys and field experiments for gathering the

information on air quality, water quality, noise quality and soil quality.

3.2 CLIMATE OF THE STUDY AREA

A. Temperature:

During the study period the minimum and maximum temperatures were recorded as

19.5 °C and 36.8°C respectively.

B. Relative Humidity:

During the study period the minimum and maximum relative humidity at project site,

was recorded from 32.00 % and 52.00 % respectively

C. Wind Pattern during Study Period

The analysis of the average wind pattern shows predominant winds from SSW, NE,

S & SSE with wind frequencies of 17.9, 10.0, 9.4 and 9.4 % respectively. The calm

conditions were prevailed for 23.50 % of the total time. Average wind speed 1.50m/s.

D. Rainfall No rainfall is observed during the study period at project site. The normal annual

rainfall in the District is 1078 mm (Source: Central Ground Water Board).

3.3 SAMPLING LOCATION DETAILS Total Six locations were selected for Base line status. Air, Water & Noise results are

presented in Table 7, 8 & 9 respectively.



3.4 AMBIENT AIR QUALITY The ambient air monitoring was carried out for 24 hours a day, twice a week for 12

week per location in the study area. Ambient Air Quality Monitoring (AAQM) was

carried out at Six locations during one month period of March 2016.

Particulate Matter (PM10): Maximum value of 68.32 μg/ m3 was recorded at

Gopavaram.

Particulate Matter (PM2.5): Maximum value of 34.87 μg/ m3 was recorded at

Ramapalem.

Sulphur Dioxide (SO2): Maximum value of Sulfur dioxide of 14.05 μg/ m3

obtained at Tupakulagudem.

Oxides of Nitrogen (NOx): A maximum value of 23.11 μg/ m3 was prevailing

at the time of sampling at Tupakulagudem.

Carbon Monoxides (CO): Maximum value of Carbon Monoxide of 0.71 mg/

m3 obtained near the sampling locations at Ramapalem.

Ammonia (NH3)

Maximum value of Ammonia of 29.20 mg/ m3 obtained near the sampling

locations at Gopavaram.



TABLE-10: THE MAXIMUM, MINIMUM & 98TH PERCENTILE VALUES FOR ALL THE SAMPLING LOCATIONS

* VOC Values monitored was Below Detectable Limit i.e 1 ppm

Code Name of

Sampling Location

PM10(µg/m3) PM2.5(µg/m3) SO2(µg/m3) NOX(µg/m3) CO (mg/m3) NH3( µg/m3)

Min Max 98th Min Max 98th Min Max 98th Min Max 98th Min Max 98th Min Max 98th

A1 Plant Site 59.40 66.90 66.75 24.20 28.90 28.72 11.9 13.5 13.5 18.10 22.60 22.46 0.45 0.53 0.53 15.20 23.10 23.00

A2 Gopavaram 62.15 68.50 68.32 19.50 25.20 25.16 8.80 11.50 11.40 16.50 18.90 18.89 0.43 0.56 0.56 21.60 29.30 29.20

A3 Ramapalem 48.80 61.80 61.58 23.14 35.14 34.87 11.20 13.20 13.14 18.12 23.11 23.11 0.44 0.72 0.71 20.40 28.70 28.52

A4 Bhimolu 52.00 58.00 57.86 17.90 26.00 25.97 5.50 7.20 7.14 16.80 19.50 19.40 0.44 0.57 0.56 22.10 29.20 29.07

A5 Surayyapeta 55.40 64.30 64.29 16.90 22.10 21.97 9.90 12.40 12.32 16.90 22.40 22.06 0.39 0.54 0.54 18.90 25.60 25.42

A6 Tupakulagudem 60.21 68.10 68.07 23.14 31.40 31.27 9.50 14.20 14.05 18.12 23.11 23.11 0.44 0.59 0.59 22.60 29.20 29.10

CPCB Standards’ 100.00 60.00 80.00 80.00 2.00 400



3.5 WATER QUALITY

Water sampling and subsequent analysis was carried out to determine both the

groundwater and surface water quality of the study area. Ground water samples are collected at 6 locations and surface water samples was

collected at 4 locations in the study area. These samples were analyzed for physical

and chemical parameters to ascertain the Baseline status in the existing surface

water and ground water bodies.

TABLE-11: WATER ANALYSIS RESULTS

S. No Parameters Ground water Surface water

Min Max Min Max

1 pH 7.08 8.29 7.09 7.66

2 Total dissolved solids (mg/l) 610.5 1325.0 297.0 606.0

3 Total hardness (mg/l) 285.0 600.0 203.0 379.0

4 Chlorides (mg/l) 94.9 419.9 79.0 139.0

5 Fluoride (mg/l) <0.5 <0.5 <0.5 <0.5

6 Sulphates (mg/l) 35.22 73.20 22.4 74.20

3.6 NOISE ENVIRONMENT Noise level monitoring was carried out at six locations during the month of March 2016.

TABLE-12: NOISE LEVELS OF THE STUDY AREA

S.No

Name of the place

Day Time

In Leq

Night Time

In Leq

CPCB NORMS

(Day time)

CPCB NORMS

(Night time) 1. Plant Site 47.9 38.2

75dB (A) 70dB (A)

2. Gopavaram 47.6 38.1 3. Ramapalem 41.9 35.3

4. Bhimolu 45.0 35.0

5. Surayyapeta 43.7 37.0

6. Tupakulagudem 45.2 33.6



Day time Noise Levels (Lday)

The day time noise levels at all the locations ranged from 41.9 dB(A) to 47.9 dB(A)

with the minimum recorded at Ramapalem (N3) and the maximum at Plant Site

(N1).

Night time Noise Levels (Lnight)

The night time noise levels ranged from 33.6 dB (A) to 38.2 dB (A), with the

minimum value recorded at Tupakulagudem (N6) and the Maximum value at Plant

Site (N1).

It is observed that the noise values obtained were within the prescribed ambient

noise Quality Standards with respect to Noise.

3.7 SOIL ENVIRONMENT On data obtained, the soil quality at around the site is appropriate and normal in

terms of soil contaminants.

3.8 LAND USE/ LAND COVER OF THE STUDY AREA

Land use / Land cover map is prepared by visual interpretation of high-resolution

satellite data (Satellite Imagery Acquisition: 25-Oct-2015) and with the help of Survey

of India Topographic maps on 1: 50,000 scale. One season data (Khariff year 2015)

is used for the delineation of different units. The units are confirmed by the ground

truth/field visits.

TABLE-13: LAND USE / LAND COVER OF THE STUDY AREA

S. No LANDUSE Area In SQM

Area in Percentage (%)

1 Built- Up Land 33.284 10.6 2 Water bodies 44.274 14.1 3 Crop Land 197.192 62.8 4 Forest 13.502 4.3 5 Wastelands 25.748 8.2

Total 314 100

3.9 DEMOGRAPHIC AND SOCIO-ECONOMIC PROFILE

This Detailed Study of the Base-Line Data of Population, Gender Ratio, Rural &

Semi-Urban Demographic Distribution, Literacy Rate, Social Amenities available in

the study Area like, Transport, Sanitation, Drinking Water, Medical & Health

Facilities, Employment Rate and other Developmental Indices of Eight Villages,



falling within 10 KMs of the Project-Influence Area and especially, that of

‘Tupakulagudem’ Village, where the project site is located, are obtained from Primary

Sources.

Of the total population of the study area of 2,17,634, Male & Female

populations are 49.68% and 50.32%, respectively.

The literate male and female in the study area are 57,536 and 53,856 which

implies that the percentage of literacy rate is 53.22% with male and 49.18%

with female respectively.

In the study area the main and marginal workers are 97,882 (44.98%) and

8603 (3.95%) respectively of the total population while the remaining 1,11,149

(51.07%) constitutes non-workers.

All the Villages, in the study area, are electrified – both for Domestic Purpose

and common facilities like, Street Lights, Public Water Pumping, etc. and also

are provided with Domestic Water.

4.0 IDENTIFICATION, PREDICTION & MITIGATION MEASURES

4.1 Air Environment - Process Emissions Details Process emission is HCl, HBr, CO2, H2 and O2 which is liberated from manufacturing

process of proposed products.

TABLE-14: EXPECTED PROCESS EMISSION DETAILS

S. No Name of the Gas Quantity In Kg/Day

Disposal Method

Polluting Process Emissions 1 Hydrogen chloride 15.00 Scrubbed by using chilled water media 2 Hydrogen Bromide 45.00 Scrubbed by using C. S. Lye solution

Non - Polluting Process Emissions 1 Oxygen 29.00 Dispersed into atmosphere

2 Hydrogen 5.00 Diffused by using Nitrogen through Flame arrestor

3 Carbon dioxide 9.00 Dispersed into atmosphere

PROCESS EMISSION CONTROL SYSTEM Scrubbers with 300 mm X 3 mtrs & 300mm X 3 mtrs capacities will be installed for

control of process emissions. The Schematic diagram of emission control system is

given below.



FIGURE-1: SCHEMATIC DIAGRAM OF EMISSION CONTROL SYSTEM

The Particulate matter generated from 6.0 TPH coal /agro waste fired boiler will be

controlled by using cyclone separator followed by bag filters. The sulphur dioxide

(SO2) and oxides of nitrogen (NOX) from boiler will be dispersed in to atmosphere by

providing adequate stack height of 32 meters for effective dispersion and dilution.

From the dispersion modeling studies conducted, it is concluded that the maximum

ground level concentration will occur. These predicted ground level concentrations

when added to Baseline scenario, the overall scenario levels of PM, SO2 and NOX

are well within the permissible limits as specified by CPCB.

4.2 Water Environment The total water requirement for proposed project is 79.71 KLD and total waste water

generated will be 40.00 KLD which is from process, floor & reactor washes, cooling

tower blow down, boiler blow down, scrubber, DM plant and domestic usage. The

effluent generation and its HTDS & LTDS effluent details are given below.

TABLE-15: EFFLUENT GENERATION DETAILS

S. No Purpose Effluent In KLD 1 Process 28.60 2 Washings 2.00 3 Boiler Blow down 4.00 4 Cooling towers Blow down 2.00



S. No Purpose Effluent In KLD 5 Scrubbing system 1.00 6 Domestic 2.40

Total 40.00

TABLE-16: HTDS & LTDS EFFLUENT DETAILS

Unit HTDS KLD

LTDS KLD

Effluent Generation

in KLD Treatment Method

Process 21.00 7.60 28.60 HTDS effluent sent to ETP with MEE System

LTDS effluents treated in ETP – RO Plant / RO Rejects to MEE System and RO permeate to reuse, Condensate from MEE to reuse and MEE residue to ATFD.

Washings 0.00 2.00 2.00 Boiler Blow down 0.00 4.00 4.00 Cooling towers Blow down 0.00 2.00 2.00

Scrubbing system 1.00 0.00 1.00

Domestic 0.00 2.40 2.40 Septic tank followed by soak pit Total 22.00 18.00 40.00

Effluent Treatment / Disposal: Zero Liquid Discharge (ZLD) concept consisting of

steam stripper, MEE system, ATFD, Biological Treatment and RO will be installed to

treat the effluents generated from plant and to reuse the treated water.

The MEE System with 45 KLD capacities and RO system with 45 KLD Capacity will

be installed for treatment of effluents generated from plant operations.

The details of MEE system given in EIA Report Chapter-10.

4.3 Noise Environment The main sources of noise pollution in the plant are Boilers, Reactors, DG Sets,

compressors and other Noise generating units. Vehicular movements during

operation phase for loading / unloading of raw materials and finished products and

transporting activity may also increases the noise levels.

All the noise generating equipments like motor’s, gear boxes and compressors are

regularly maintained with lubricating material to avoid noise generation. All the DG

sets are providing with acoustic enclosures. A thick greenbelt will be developed

along the periphery of the plant boundaries to minimize the noise pollution from the

source.



4.4 Land Environment

The proposed plant activities are unlikely to alter the land-use pattern in the project

site. The unit will take adequate measures for storage, handling and disposal of

hazardous waste. Hence, there will be no significant adverse impact on land

environment.

4.5 Ecological Environment Detailed flora and fauna studies were carried in the study area. As per baseline

studies, there are no endangered, threatened & protected plants and animal species

were recorded in the study area. Hence, no significant adverse impact is envisaged

on ecology.

4.6 Hazardous /Solid Waste The Hazardous / Solid waste generated and disposal methods from proposed project

are given below.

TABLE-17: HAZARDOUS/SOLID WASTE & HAZARDOUS WASTE GENERATION, DISPOSAL DETAILS

S. No Name of the Hazardous Waste

Quantity In

Kgs/Day Disposal Method

1 Organic waste (Process Residue-574 + solvent Distillation Residue-95)

669.00 Sent to Cement Industries

2 Spent Carbon 15.00 Sent to Cement Industries 3 MEE Salts 465.00 Sent to TSDF 4 ETP Sludge 30.00 Sent to TSDF

5 Used Oils 50L/Annum SPCB Authorized Agencies for Reprocessing/Recycling

6 Detoxified Containers 300 No’s / Month

After Detoxification sent back to suppliers/SPCB Authorized Parties

7 Used Lead Acid Batteries 2 No’s/ Annum

Send back to suppliers for buyback of New Batteries

Solid Waste Details

8 Ash from boiler & Thermo pack boiler 7600.00 Sent to Brick Manufacturers

4.7. Risk Assessment and Disaster Management Plan

The Risk assessment studies have been conducted for identification of hazards, to

calculate damage distances and to spell out risk mitigation measures. The details

are discussed in detail in Chapter – 7 of EIA Report.



5.0 ENVIRONMENTAL MANAGEMENT PLAN 5.1 ENVIRONMENT MANAGEMENT PLAN FOR CONSTRUCTION PHASE

Adequate and effective environment protection measures will be planned and

designed to minimize the impacts due to activities related to pre-construction

(preparatory phase) of the project, machinery installation and commissioning stages

and end with the induction of manpower and start up. The impacts identified during

the construction phase are mainly due to site preparation, foundation work, material

handling, and construction of buildings and installation of the machinery.

All possible care will be taken to reduce the noise levels due to construction activity.

Also, noise prone activities shall be restricted to the extent possible during night

particularly during the period of 10 PM to 6 AM in order to have minimum

environmental impact.

5.2 ENVIRONMENT MANAGEMENT PLAN FOR OPERATIONAL PHASE

A) Air Pollution Management

Gaseous emissions from reactions shall be scrubbed in a two stage scrubber

to control the gaseous emissions into the atmosphere.

Fugitive emissions will be reduced by providing vent condensers to the

storage tanks and all the reactors are will be provided with primary and

secondary condensers with chilled brine circulation to avoid fugitive emissions

and solvent losses which ensures the recovery up to 95% and also controlled

by closed operations and suitable handling methods.

Adequate stack height of 32 meters will be provided to the proposed boilers

for effective dispersion of pollutants’ and stack monitoring facilities for the

periodic monitoring of the stack to verify the compliance of the stipulated

norms.

To prevent the particulate matter delivering from the boilers will be arrested by

providing Cyclone separator followed by Bag filters. B) Water Pollution Management

The HTDS effluents will be collected and treated in steam stripper, MEE system &

ATFD. Condensate along with LTDS effluent will be sent to biological treatment

including R.O system for treatment and reuse. There will be no discharge of effluent



outside the plant premises. The unit will be treated as ZLD unit. Salts from ATFD

and sludge from the ETP will be sent to TSDF for land fill.

C) Noise Pollution Management

Extensive oiling, lubrication and preventive maintenance will be carried out for

the machineries and equipments to reduce noise generation.

Green Belt Development around plant boundaries and within plant in an area

of 2.45 Acres (9914.8 SQM).

A thick Greenbelt along the periphery of the compound wall arrests the Noise

pollution from the plant.

D) Hazardous Waste Management The hazardous wastes generated from the industry will be from distillation/process,

ETP sludge, Process organic residues, process Inorganic residues, MEE salts, spent

catalyst/spent carbon, discarded containers and bags which will properly stored in

a hazardous waste storage area with leachate collection system and then

transported and properly disposed.

The entire organic residues will be disposed to cement industries for incineration and

Inorganic residues sent to TSDF for secure land fill.

E) Green Belt The industry proposed to develop greenbelt on all sides of the industry in an area of

2.45 Acres (9914.8 SQM) from the total area of 7.00 Acres (28328SQM) of land, with

an amount of Rs.5,00,000 /- for greenbelt. The amount will be spent during the

period of five years. First year amount will be Rs.2,00,000 for plantation. Second

year amount will be Rs.1,00,000/- for development of plants. Third year amount will

be Rs. 1, 00,000/- for maintenance and development. Fourth & Fifth year amount will

be Rs. 50,000/- & Rs. 50,000/- for development. A list of plants suitable for greenbelt

and to the local agro climatic conditions is given in the EIA report.

F) Solvent Recovery

The solvents like Acetone, Ethanol etc will be recovered up to 95% by using

distillation.



5.3 ENVIRONMENT MANAGEMENT CELL

Vensar Laboratories Pvt. Ltd will provide a dedicated Environmental Management

Cell with trained staff to look after the proper environmental management of the

proposed plant including operation & maintenance of all facilities.

5.4 ENVIRONMENT MONITORING PROGRAM Regular monitoring of environmental parameters is of immense importance to

assess the status of environment during project operation. The regular monitoring

will be carried out with the MoEF&CC/NABL recognized laboratory.

6.0 ROOF WATER HARVESTING Rainwater harvesting is a mechanism involved in collecting, storing and using. A

rainwater harvesting system comprises various stages – flow of rainwater through

pipes or drains, filtration and storage in tanks for reuse or recharge.

Roof top area is considered for harvesting rainwater for this project and other areas

are excluded due to possibility of chemical contamination. Roof top rainwater

harvesting is one of the appropriate options for augmenting ground water recharge/

storage in urban areas where natural recharge is considerably reduced due to

increased urban activities and not much land is available for implementing any other

artificial recharge measure.

FIGURE-3: ROOF WATER HARVESTING STRUCTURE



7.0 EMP BUDGET

The unit has proposed for 100.0 Lakhs as capital cost and 19.0 Lakhs as recurring

cost for environment pollution control measures.

TABLE-18: PROPOSED BUDGETS FOR ENVIRONMENTAL MANAGEMENT

PLAN [EMP]

S. No Particulars Proposed

Capital Cost (Rs. Lac)

Recurring Cost

(Rs. Lac)

1 Pollution Control Equipment (Scrubbers, Cyclone separator, Bag filter , Sampling port arrangements etc.,)

5.0 1.0

2 ZLD System (MEE , RO, necessary modification of ETP system)

85.0 12.0

3 Rain Water Harvesting (Roof top water collection pit and Roof top water towards the rain water harvesting pit)

3.0 0.0

4 Green Belt Development (Plantation and Maintenance) 4.0 1.0

5 Health & Safety (PPEs, Medical Surveillances Expenses etc.,) 3.0 3.0

6

Environmental Monitoring (Air, Water, Noise, VOCs, Boiler Stack flue gases, DG sets stack monitoring expenses etc.,)

0.0 2.0

Total 100 19

8.0 SOCIO-ECONOMIC DEVELOPMENT

It is predicted that socio-economic impact due to this project will positively increase

the chance of more employment opportunities for local peoples. There are no

Resettlement and Rehabilitation issues involved in this project. The project

infrastructures will be of use to people of the area. The revenue of the village will be

definitely increasing due to the project.

9.0 PROJECT BENEFITS

Proposed project will result in considerable growth and up liftments of local

community in the nearby villages by providing the employment. The proposed project

will generate direct and indirect employment to the nearby villages and the

unavailable technical persons will be recruited from outside.



10.0 CONCLUSION Vensar Laboratories Pvt. Ltd has committed to implement all the pollution control

measures to protect the surrounding environment – adapting Zero-Liquid-Discharge

System for all its Effluents, by controlling process emissions and Safe-Disposal of all

Solid Wastes – generated either as process wastes or packing wastes. The project

can definitely improve the regional, state and national economy. Industrial growth is

an indication of all-round Socio-Economic Development – by generating local

Employment and Business Opportunities. The implementation of this project will

definitely improve the physical and social infrastructure of the surrounding area.

CHAPTER -I

INTRODUCTION


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter - I Page 1

CHAPTER- I INTRODUCTION

1.1 IDENTIFICATION OF PROJECT & PROJECT PROPONENT

1.1.1 IDENTIFICATION OF THE PROJECT

Vensar Laboratories Pvt Ltd proposes to establish a Bulk Drug & Intermediates

manufacturing unit at Survey No: 32, Tupakulagudem (V) Tallapudi (M), West Godavari

(Dist.), Andhra Pradesh.

The industry proposes to establish unit in an area of 7.00 Acres (28328.00SQM). The

Industry is having its administrative office at Duplex No: 12,

Lakshmi Gayatri Enclave, Aditya Nagar, KPHB, Kukatpally, Hyderabad. The proposed

project cost is about Rs.6.00 Crores, which includes construction of the buildings,

equipment, machinery and greenbelt development.

Gopavaram village is at a distance of 1.43 KMs in N Direction from the site.

Kovvur is a Town; it is at a distance of 20 KMs in SE side from the project site.

Site is at a distance of 24 KMs from Rajahmundry in SE direction.

Nearest State Highway from the site is SH-42 (Koyyalagudem- Nallajerla) at a

distance of 17 KMs in W side from the project site.

Nearest National Highway from the site is NH-5 (Rajahmundry - Anakapalle) at a

distance of 26KMs in SE side from the project site.

The co-ordinates of the proposed location are Latitude: 17009’27.76” North and

Longitude: 81035’32.23” East.

The Industry intends to manufacture Bulk Drugs, requires Environment Clearance, from

MoEF&CC, GOI, New Delhi and Consent for Establishment and Consent for Operations

from State pollution control Board.



1.1.2 ABOUT THE PROMOTERS

Mr. Penmetsa Subramanyam Raju, Managing partner of the company is young and

energetic personality with vast experience in pharmaceutical industry

Mr. Subramanya Raju has work experience of more than 18 years in bulk drugs industry.

He has worked in senior position as Director-manufacturing in Vasudha group of industries

and helped to emerge as one of the leading group in bulk drug industry. During his tenure

in Vasudha Pharma Chem Limited, he had managed 3 units situated in jeedimetla,

kazipally, and Visakhapatnam looking after production, research and development,

packing, dispatch of the finished intermediates and APIs at right time, conforming to the

specifications. Added to this, he is actively involved in discussing with the customers for

extracting business by increasing the yields and reducing production cost to meet the

demand of the customers. He has visited many countries in Europe & Asia for exhibiting

the bulk drug products. Mr. Subramanyam Raju is also Managing Partner of Sri

Venkateswara Industries which manufactures the intermediates & bulk drugs, situated in

Hyderabad. Considering his skills and abilities, M/s Shree Jaya Laboratories Pvt Ltd., have

offered him the post of Director during February 2012 and he assumed charge of the

Director during February 2012 and has taken charge as Chairman during April 2013

looking after the entire production, research and development activities of the organization.

He has improved the turnover of the company from 28 crores to 120 crores within a short

span of one year.

Mr. Subramanyam Raju is experienced in manufacturing, process development, project

management, scale up to operations, quality systems and the aqua culturing technically.

Mr. Subramanyam Raju was also awarded Hon. Doctorate by the international university in

Colombo during November 2013. He has also acquired more than 20acres of land in west

Godavari district of Tallapudi Mandal for establishment of Vensar and Vensub laboratories

for manufacturing APIs. All the relevant licenses for commencement of the units were

obtained and the land is made ready for construction works.

Dr. Pericherla Kasiviswanadharaju, the partner of the company is technically qualified

person, having rich experience in organic synthesis. He recently finished his Ph.D from

prestigious institute BITS Pilani, Rajasthan and his technical background is an additional

asset to the industry. Presently, he is involved in purchase, marketing and research and

development departments.



1.2 PURPOSE OF THE REPORT

As per the notification No.J-11031/41/2006-IA-II (I) dated 14th September 2006, and

circular dated 13th October 2006, issued by the Ministry of Environment and Forests (IA

Division), GOI, New Delhi. Vensar Laboratories Pvt. Ltd falls under 5 (f) A category and

requires Environmental Clearance. The industry engaged the services of Rightsource

Industrial Solutions Pvt. Ltd, Hyderabad to prepare and submit the necessary documents.

The consulting firm has submitted an application in prescribed FORM-I along with

necessary enclosures for obtaining Terms of Reference to IA Division, MoEF&CC, GOI,

and New Delhi.

The project proposal was considered and appraised by the Expert Appraisal Committee

(EAC) in its meeting held during 22nd – 23rd December 2014. The EAC – MoEF&CC has

given Terms of Reference vide letter F. No. J-11011/368/2014 - IA II (I) Dated 10th March

2015 & 8th September 2016. As per Issued TOR - EIA Study was carried out with

necessary Environmental Monitoring during the month of March 2016.

1.3 OBJECTIVE AND SCOPE OF THE STUDY 1.3.1 OBJECTIVE The objective of the study is to carry out Environmental Impact Assessment (EIA) for the

proposed project to meet the Environmental compliances laid down by the Ministry of

Environment, Forest & Climate Change (MoEF&CC), Government of India and issued a

circular making it mandatory to obtain Environment Clearance for 65 categories of

industries. Bulk Drug & intermediates is one of them, occupying 5th place.

Ministry of Environment, Forest and Climate Change (IA Division) issued the notification as

No.J-11031/41/2006-IA-II (I) on 14th September 2006 and circular on 13th October 2006.

The study would include the description of project setting, appraisal of project activities and

assessment of adverse impacts related to the location, design, construction and operation

of the project. Environmental Management Plan (EMP) will be prepared that includes

mitigation measures, including evaluation of alternatives to reduce or mitigate/eliminate the

impacts that likely to cause most significant environmental burdens.

As per the above notification the industry seeks Environment Clearance from MoEF&CC,

GOI, New Delhi, and Consents from State Pollution Control Board is not attached since

the same is to be obtained, after obtaining the EC.

Preparation of Environmental Impact Assessment Report (EIA) based on summer month of

March 2016, which would be used as management planning tool for better Environmental



Management by suggesting control measures to avoid pollution problems arising out of the

project. The report will include a detailed Environmental Management Plan (EMP). The

study will be carried out incorporating all the details and requirements of State Pollution

Control (SPCB) and Ministry of Ministry of Environment, Forest and Climatic Change as

per their requirements.

1.3.2 SCOPE OF STUDY 1.3.2.1 ENVIRONMENTAL IMPACT ASSESSMENT

To assess the impact of the project on Land use, Ambient Air Quality, Water

Quality, Noise levels, Ecology & Biodiversity, Hydrology & Geology, and Socio-

economic status of area.

To prepare Environmental Management Plan (EMP) for mitigating adverse

impacts due to proposed project.

Collection and testing of water sources and soil.

To prepare environmental monitoring plan for operational phase.

Green Belt development

1.3.2.2 SOCIO-ECONOMIC ASSESSMENT

Socio-Economic Aspect: As this is a small Bulk Drug & intermediates Manufacturing Unit,

which construction doesn’t disturb any existing Habitat, no Resettlement & Rehabilitation

required, for this project activity.

1.3.2.3 REGULATORY SCOPING

Obtaining Consent for Establishment

Obtaining Consent for Operation from State Pollution control board.

1.3.2.4 JUSTIFICATION OF THE PROJECT.

Vensar Laboratories Pvt. Ltd proposes to establish a Bulk Drug & Intermediates

manufacturing unit. These bulk drugs are used in the manufacture of medicines, most of

which are life saving drugs. The demand of such products is tremendous in our country

and there is a huge gap in the demand and supply chain. The market of these products

has a fast progressing growth and there is ample opportunity in indigenous as well as

export market. Easy availability of Raw materials, Infrastructure and Man power. This

result in the availability of cheaper products than imported products and also revenue to

the state. Due to the above reasons, hence it is justified to set up an industry at the

location.



1.4 PROJECT LOCATION AND COMPLIANCE OF SITE WITH SELECTION CRITERIA. TABLE 1.1: PROJECT LOCATION AND COMPLIANCE OF SITE.

Project location Details

Latitude & Longitude Latitude: 17009’27.76” North Longitude: 81035’32.23” East.

Climatic Conditions

Annual Max Temp is 36.8.0C Annual Min Temp is 19.50C (Source: Hand Book of Statistics, West Godavari) Normal Annual Rainfall is 1078 mm

Land acquired for the plant 7.0 Acres (28328.00SQM) Land use Private Land Nearest Village Gopavaram Village – 1.43 KMs (N) Nearest Town Kovvur- 20 KMs (SE)

Major urban Settlements Rajahmundry - 24 KMs (SE) Nearest National High way Nearest State High way Nearest Railway station Nearest Airport

National Highway No: (NH- 5) -26 KMs (SE) (Rajahmundry – Anakapalle) State Highway No: (SH-42) - 17 KMs (W) (Koyyalagudem - Nallajerla) Kovvur Railway station – 22.0 KMs (SE) Rajahmundry Airport (Madhurapudi)– 24.00 KMs (ESE)

National Parks Nil [within 10 KMs radius] Major Industries near the plant site Andhra Sugars Limited (Chemicals & Fertilizers Unit)

Wild life sanctuary Nil [within 10 KMs radius]

Water Bodies

Tadipudi lift canal – 1.50 KMs (S) Tank near Bhimolu – 2.65 KMs (SW) River Godavari– 7.8 KMs (E) Kovada kalva - 6.25 KMs (N) Polavaram Right Canal - 3.5 KMs (WNW) Tank near Ramannapalem – 7.80KMs(N) Pendrala kalva - 8.4 KMs (NW) Kovvada Kalva Reservoir – 9.62 KMs (NW)

Reserve Forest

Fairly dense jangle near Gopavaram - 1.2(WNW) Dense Mixed jangle near Hukumpet - 4.8 KMs (NNW) Mixed jangle near Rajampalem - 5.1KMs (NNW)

Vinjaram R.F. -9.1 KMs(NNW) Karakapadu RF – 9.4 KMs (NW)

Polavaram RF- 9.6 (N) Historical Places Nil [within 10 KMs radius]

Socio-Economic

This Study Report covers Population, Gender Ratio, Rural & Semi-Urban Demographic Distribution, Literacy Rate, Social Amenities available in the study Area like, Transport, Sanitation, Drinking Water, Medical & Health Facilities, Employment Rate and other Developmental Indices of Eight Villages falling within the 10 KMs Radius of the proposed Project Site.



1.5 REGULATORY FRAMEWORK

The MoEF&CC, CPCB and SPCBs together form the regulatory and administrative core of

the sector. Legislation for environmental protection in India for chemical industry is mainly

EIA Notification- 2006, Water (Prevention & Control of Pollution) Act-1974, Air (Prevention

& Control of Pollution) Act-1981, Water (Prevention and Control of Pollution) Cess Act,

1977; Hazardous Wastes (Management, Handling and Transboundary Movement) Rules

2008, amended time to time etc are major Act/rules/notification applicable to industry.

1.6 LEGAL POLICY AND INSTITUTIONAL FRAMEWORKS

The principal environmental regulatory authority is the Ministry of Environment & Forests

(MoEF&CC), New Delhi which formulates environmental policies and accords

environmental clearances for different projects. Table 1.2 highlights the relevant

environmental legislations applicable to the proposed project.

TABLE 1.2: APPLICABILITY OF LEGAL POLICIES TO THE PROJECT

S. No Legal frame work coordinating authority

Objectives of the policy

Applicability to the proposed

project Environmental Legality

1 Water (Prevention and Control of pollution) Act 1974

CPCB

Prohibits the discharge of pollutants into water bodies beyond a given standard, and lays down penalties for non-compliance

Applicable

2

Water (Prevention and Control of Pollution) Cess Act, 1977

SPCB

Provides for a levy and collection of a cess on water consumed by industries and local authorities

Applicable

3

Forest (Conservation) Act 1980, Forest Conservation Rules, 1981

MoEF&CC, Forest Department (SFD)

Restrictions on conversions of Forest for uses other than reforestation, including use for roads

Not Applicable

4 Air (Prevention and Control of Pollution) Act, 1981

CPCB Provides means for the control and abatement of air pollution.

Applicable

5 The Air(Prevention and Control of Pollution) Rules, 1982

CPCB

Defined the procedures for conducting meetings of the boards, the powers of the presiding officers, decision-making etc

Applicable

6 Environment (Protection) Act 1986 (EPA) followed by

Ministry of Environment and Forests

Ensure that appropriate measures are taken to conserve and protect the

Applicable






project amendment in May1994 (Schedule-I)

(MoEF&CC) Environment before commencement of operations.

7

Environmental Impact Assessment Notification no. S.O. 60 (E) 1994,

MoEF&CC

Under its ambit, 32 types of industries are liable to opt for Environmental clearance from MoEFCC, by providing adequate EIA report

Applicable

8 The Environment (Protection) Rules, 1986

CPCB

Lay down the procedures for setting standards of emission or discharge of environmental pollutants

Applicable

9

The Hazardous Wastes management (Management and Handling) Rules, 1989

SPCB

Procedure for inventory, control, handling and disposal of hazardous waste. Provide for setting up of disposal sites/landfill sites design, operation and closure

Applicable

10 Bio Medical Waste (Management & Handling) Rules, 1998

SPCB

Provide for collection, segregation, storage, treatment and disposal of biomedical wastes according to the standards and procedures

Not Applicable

11 Wildlife Protection Act 1972 MoEF&CC

Protection of wildlife (wild animals, defined plants and birds) in either National Parks or sanctuaries

Not Applicable

Social legal framework

12 Land Acquisition Act 1894

Respective State Governments

Provides for the acquisition of land for public purposes and for Companies and for determining the amount of compensation to be made on account of such acquisition.

Not Applicable.

Other relevant legal Framework

13 Central Motor Vehicles Act, 1988

Ministry of Road Transport and Highways / Traffic Department

To control vehicular air and noise pollution. To regulate development of the transport sector, check and control vehicular air and noise pollution.

Not Applicable






project

14

The Ancient Monuments and Archaeological Sites and Remains Act 1958

Archaeological Survey of India (ASI)

Provides for the preservation of ancient and historical monuments and archaeological sites and remains of national importance

Not Applicable

Handling of Radioactive Isotopes

15 Atomic Energy Act, 1962

AERB/BARC / GoI

Handling and use of radioisotopes Not Applicable

16

Atomic Energy (Radiation Protection) Rules, 2004

AERB / BARC / GoI

Handling and use of radioisotopes and management and prevention of harmful radiation generated from therein

Not Applicable

17

Radiation Surveillance Procedures for Medical Applications of Radiation , 1989

AERB/ BARC/ GoI

Surveillance of Radiations generated in any premises associated with handling of radioactive substances.

Not Applicable

18

AERB Safety Code No. AERB /SC / MED (Rev-1),2001

AERB / BARC / GoI

Sets out safety methods for radiation / nuclear medicine laboratories

Not Applicable

PROJECT DESCRIPTION

CHAPTER -II


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter - II Page 1

CHAPTER-II PROJECT DESCRIPTION

2.1 TYPE OF THE PROJECT


manufacturing unit at Survey No: 32, Tupakulagudem (V), Tallapudi (M), West


The industry proposes to establish unit in an area of 7.0 Acres (28328.00SQM). The

Industry is having its administrative office at Duplex No: 12,

Lakshmi Gayatri Enclave, Aditya Nagar, KPHB, Kukatpally, and Hyderabad.

The proposed project cost is about Rs. 6.00 Crores, which includes construction of

the buildings, equipment, machinery and greenbelt development.

2.2 LOCATION




The industry proposes to establish unit in an area of 7.0 Acres (28328.00SQM).

.

2.3 PROPOSED SCHEDULE FOR APPROVAL AND IMPLEMENTATION

The industry intends to obtain approval within one year and to implement the

recommendations. The industry proposes to implement the recommendations of the

Authorities from construction stage.



FIGURE 2.1: LOCATION MAP



FIGURE 2.2: GOOGLE EARTH MAP SHOWING ROUTE MAP OF PROJECT SITE LOCATION



FIGURE 2.3: GOOGLE EARTH MAP SHOWING PROJECT SITE



FIGURE 2.4: LATEST PHOTOGRAPHS OF PLANT SITE



FIGURE 2.5: TOPO MAP SHOWING 10 KMs RADIUS



2.4 SITE / INFRASTRUCTURE DETAILS:




The plant has an area of 7.0 Acres (28328.00SQM) and falls at the intersection of

Latitude: 17009’27.76” North, Longitude: 81035’32.23” East. The nearest railway

station is Kovvur Railway station which is around 22.0 KMs (SE). The land usage

details are given in Table 2.1.

Note: Route map to be imposed.

TABLE 2.1: PROPOSED LAND USE DETAILS

S. No Description Area

(SQM)

Area

(Acres)

1 Built up land 10764.64 2.66

2 Greenbelt area 9914.8 2.45

3 Roads area 5382.32 1.33

4 Open

area/Parking 2266.24 0.56

Total 28328.00 7.00

More than 33% of Land Allotted For Green Belt



FIGURE 2.7: SITE PLAN


Prepared By Rightsource Industrial Solutions Pvt. Ltd Chapter – II Page 9

2.5 PROCESS DESCRIPTION

The manufacturing process of bulk drugs consists of chemical synthesis extending to

stages of processing involving different type of chemical reactions. Total production

capacity of proposal will be 10 MT/Month. (Given in Table – 2.2). The unit will take

adequate control measures for storage and handling of Raw materials, solvents and

cylinders with in factory premises.

TABLE 2.2: LIST OF PROPOSED PRODUCTS AND CAPACITIES

S. No Product Name CAS Number


Application

Quantity In

Kgs/Month

Quantity In

Kgs/Day 1 Carvedilol 72956-09-03 Cardiovascular 5000.00 166.67

2 Citalopram Hydro Bromide 59729-32-7 Antidepressant 2000.00 66.67

3 Ketrolac tromethamine 74103-06-3 Anti-

inflammatory 5000.00 166.67

4 Ramipril 87333-19-5 Cardiovascular 5000.00 166.67

5 Sertraline Hydrochloride 79559-97-0 Antidepressant 5000.00 166.67

6 Terbinafine Hydrochloride 78628-80-5 Antifungal 4000.00 133.33

7 Tramadol Hydrochloride 36282-40-0 Analgesic 5000.00 166.67

Total (Worst combination of any two products on

campaign basis only) Total 10000.00 333.33

TABLE 2.3: LIST OF BY- PRODUCTS AND QUANTITIES

S. No Name of the Product

Name of the By-Product

Quantity In Kg/Day

Disposal Option

1 Citalopram hydro bromide Magnesium chloride 32.00 For Sale

2 Ramipril Triethyl amine Hydrochloride 215.00 For Sale

3 Terbinafine Hydrochloride Potassium chloride 31.00 For Sale



2.5.1 MANUFACTURING PROCESS OF THE PRODUCTS

MANUFACTURING PROCESS

1. CARVEDILOL

Process description: Stage-1

9H-carbazol -4-ol reacts with (chloromethyl) oxirane to give Stage-1 compound in presence of Tetrahydrofuran.

Stage-2

Stage-1 compound condensed with 2-(2-methoxyphenoxy) ethylamine in the

presence of Ethyl acetate to give Carvedilol as product.



CARVEDILOL Route of synthesis: Stage-1

NH

OH

9H-Carbazol-4-olC12H9NO

183.21

+

(Chloromethyl)oxirane

OCl

C3H5ClO

92.52

THFNH

O O

4-Oxiranylmethoxy-9H-carbazole

C15H13NO2

239.27

HCl

36.46

+

Stage-2

NH

O O

4-Oxiranylmethoxy-9H-carbazole

C15H13NO2239.27

+

2-(2-methoxyphenoxy)ethylamine

NH2

OO

C9H13NO2

167.21

Ethyl acetate

NH

O NH

OH

O

H3CO

CarvedilolC24H26N2O4

406.47



CARVEDILOL

Flow Chart:

4(Oxiranyl methoxy)-9H-Carbazole(2-methoxyphenoxy)ethylamineEthyl acetateMethanol

Stage-2Ethyl acetate RecMethanol Rec

CARVEDILOL

Stage-19H-Carbazol-4-ol(Chloromethyl) oxiraneTetrahydrofuran

Tetrahydrofuran Rec



CARVEDILOL

Material Balance:

Material balance of Carvedilol Stage-1

Batch Size:500.0 0Kg Name of the input Quantity

in Kg Name of the out put Quantity

In Kg 9H-Carbazol-4-ol 226.00 Stage-1 295.00 (Chloromethyl) oxirane 114.00 Tetrahydrofuran Recovery 855.00 Tetrahydrofuran 900.00 Tetrahydrofuran loss 45.00 Toluene 1000.00 Toluene Recovery 950.00 Sodium sulfate 250.00 Toluene Loss 50.00 Water 200.00 Inorganic waste 250.00 (Sodium sulfate) Effluent water 200.00 (Water-200) Process Emission 45.00 (Hydrogen chloride) Total 2690.00 Total 2690.00

Material balance of Carvedilol Stage-2

Batch Size:500.0 0Kg Name of the input Quantity


In Kg Stage-1 295.00 Carvedilol 500.00 (2-methoxyphenoxy)ethylamine 206.20 Ethyl acetate Recovery 760.00 Ethyl acetate 800.00 Ethyl acetate Loss 40.00 Sodium chloride(washing) 50.00 Effluent water 550.00 Activated carbon 20.00 (Water-500,Sodium chloride-50) Sodium sulfate 250.00 Spent Carbon 20.00 Water 500.00 Inorganic waste (Sodium sulfate) 250.00 Organic residue 1.20 Total 2121.20 Total 2121.20



2. CITALOPRAM HYDROBROMIDE

Process Description:

Stage-1

5-Cyanophthalide reacts with 4-fluorophenylmagnesiumChloride and (Dimethylamino) propyl magnesium chloride to give Stage-1 compound in presence of Toluene. Stage-2

Stage-1 compound reacts with Hydrogen bromide to give Citalopram Hydro bromide in presence of Sulfuric acid, Acetone and Water.



CITALOPRAM HYDROBROMIDE

Route of synthesis:

Stage-1

MgCl

F

4-Fluoro benzene Magensium chloride

C6H4MgClF

ClMg NCH3

CH3

Dimethyl amino propyl magnesium chloride

C5H12MgClN

145.91

+ +

ONC

O

5-Cyano phthalide

C9H5NO2

159.14

+ 2 HCl

OH

OH

F

NCH3

NC

CH3

4-[4-Dimethylamino-1-(4-fluoro-phenyl)-1-hydroxy-butyl]-3-hydroxymethyl

-benzonitrileC20H23FN2O2

342.41

+

154.85

72.92

Toluene

2 MgCl2

190.42



Stage-2

OH

OH

F

NCH3

NC

CH3

4-[4-Dimethylamino-1-(4-fluoro-phenyl)-1-hydroxy-butyl]-3-hydroxymethyl-benzonitrile

C20H23FN2O2

342.41

H2SO4, H2O , Acetone

O

F

NC

NCH3

CH3

+ HBr

80.91

. HBr

Citalopram hydrobromide

C20H22BrFN2O

405.30

+ H2O

18.02




Flow chart:

Hydrogen bromideSulfuric acidAcetoneCarbon and Hyflow

Stage-2 Acetone Recovery

Citalopram hydro bromide

Stage-1

5-Cyanophthalide4-fluorophenylmagnesiumchloride(Dimethylamino)propyl magnesium chlorideHydrochloric acidToluene

Toluene Recovery




Material Balance

Material balance of Citalopram hydro bromide Stage-1

Batch Size:400.00Kg Name of the input Quantity


In Kg 5-Cyanophthalide 158.00 Stage-1 338.00 4-fluorophenylmagnesium chloride

154.00 Toluene Recovery 237.00

(Dimethylamino)propyl magnesium chloride

145.00 Toluene Loss 13.00

Hydrochloric acid 72.40 By-Products 189.00 Toluene 250.00 (Magnesium chloride) Water 500.00 Effluent water 500.00 (Water-500) Organic residue 2.40 Total 1279.40 Total 1279.40

Material balance of Citalopram hydro bromide Stage-2

Batch Size:400.00Kg Name of the input Quantity


In Kg Stage-1 338.00 Citalopram hydro bromide 400.00 Hydrogen bromide 80.00 Acetone Recovery 475.00 Sulfuric acid 10.00 Acetone Loss 25.00 Acetone 500.00 Effluent water 528.00 Activated Carbon & Hyflow 5.00 Spent Carbon & Hyflow 5.00 Water 500.00 (Water-500,Generated water-18,

Sulfuric acid -10)

Total 1433.00 Total 1433.00



3. KETOROLAC TROMETHAMINE

Process Description

Stage-1

5-chloro-2-benzoylpyrrole reacts with Methyl-gama-methoxy –butanoate to give Stage-1 compound in presence of Acetone. Stage-2 Stage-1 compound undergoes condensation with Tromethamine to give Ketorolac Tromethamine in presence of Acetone



KETOROLAC TROMETHAMINE

Route of synthesis

Stage-1

HN Cl

O

5-Chloro-2-benzoyl pyrrole

C11H8ClNO

205.64

+

methyl-gama-methoxybutanoate

OCH3O

H3C

O

C6H12O3

132.16

+ NaOH

40.00

N

O

COOH

Ketorolac

C15H13NO3

255.27

+ NaCl

58.44

+ 2 CH3OH

64.08

Acetone



Stage-2

N

O

COOH

Ketorolac

C15H13NO3

255.27

Tromethamine

NH2

HO OH

OH

+

C4H11NO3

121.14

Acetone

N

O

COOH

NH2

HO OH

OH

.

ketorolac tromethamineC19H24N2O6

376.40




Flow chart:

Stage-1AcetoneTromethamineCarbon & hyflow

Stage-2 Acetone Recovery

Ketorolac Tromethamine

Stage-1

5-chloro-2-benzoylpyrroleMethyl-gama-methoxy butanonateSodium hydroxideAcetone

Acetone Recovery




Material balance

Material Balance of Ketorolac Tromethamine Stage-1

Batch Size: 500Kg Name of the input Quantity


in Kg 5-chloro-2-benzoylpyrrole 783.00 Stage-1 410.00 Methyl-gama-methoxy butanonate

300.00 Acetone Recovery 880.00

Sodium hydroxide 90.00 Acetone Loss 45.00 Acetone 1000.00 Methanol Recovery 143.00 Water 20200.00 Effluent water 20331.00 (water-20200,Sodium chloride-

131)

Organic Residue 564.00 (Organic Impurities-489,

Acetone-75)

Total 22373.00 Total 22373.00

Material Balance of Ketorolac Tromethamine Stage-2

Batch Size: 500Kg Name of the input Quantity


in Kg Stage-1 410.00 Ketorolac Tromethamine 500.00 Acetone 1000.00 Acetone Recovery 880.00 Tromethamine 458.00 Acetone Loss 45.00 Carbon & hyflow 10.00 Effluent water 22000.00 Water 22000.00 (water-22000) Spent carbon & hyflow 10.00 Organic residue 443.00 Organic impurities-368,Acetone-

75)

Total 23878.00 Total 23878.00



4. RAMIPRIL

Process description:

Stage-1

2-(1-carboxy-ethylamino)-4-phenyl-butyric acid ethyl ester undergoes condensation with (cis, endo)-octahydro-cyclopenta[b]pyrrole-2(s)-carboxylic acid to give Stage-1 compound in presence of Ethyl acetate and Triethylamine. Stage-2 Stage-1 compound Purification with Ethanol to give Ramipril



RAMIPRIL

Route of synthesis:

Stage-1

2-(1-Carboxy-ethylamino)-4-phenyl-butyric acid

ethyl esterC15H21NO4

279.33

+

(Cis,endo)-octahydro-cyclopenta[b]pyrrole-2(S)-carboxylic acid

HN

O OH

H H

HN

OH3C

O

OH

O

CH3

C8H14ClNO2191.66

Ethylacetate

Triethylamine

HN

OH3C

O O

CH3

N

O OH

H H

1-[2-(1-Ethoxycarbonyl-3-phenyl-propylamino)-propionyl]-octahydro-cyclopenta[b]pyrrole

-2-carboxylic acid(Ramipril crude)C23H32N2O5

416.51

+ H2O

18.02

.+ (C2H5)3N

101.19

(C2H5)3N HCl

137.65

+

HCl



Stage-2

HN

OH3C

O O

CH3

N

O OH

H H


-2-carboxylic acid(Ramipril crude)C23H32N2O5

416.51

HN

OH3C

O O

CH3

N

O OH

H H


-2-carboxylic acid(Ramipril pure)C23H32N2O5

416.51

Ethanol



RAMIPRIL

Flow chart:

Stage-1Ethanol5% Pd/Activated carbon

Stage-2 Ethanol recovery

Ramipril

Stage-1

2-(1-carboxy-ethylamino)-4-phenyl-butyric acid ethylester(cis,endo)-octahydro-cyclopenta[b]pyrrole-2(s)-carboxylic acidEthyl acetateTriethylamine

Ethyl acetate RecoveryTriethylamine Recovery



RAMIPRIL

Material Balance

Material balance of Ramipril Stage-1

Batch Size: 500.00Kg Name of the input Quantity


In Kg 2-(1-carboxy-ethylamino)-4-phenyl-butyric acid ethylester

343.00 Stage-1

510.00

(cis,endo)-octahydro-cyclopenta[b]pyrrole-2(s)-carboxylic acid hydrochloride

236.00 By-Product 645.00

Ethyl acetate 600.00 (Triethyl amine Hydrochloride)

Triethylamine 600.00 Ethyl acetate Recovery 570.00 Water 100.00 Ethyl acetate Loss 30.00 Effluent water 122.15 (water-100,Generated water-

22.13)

Organic residue 1.85 Total 1879.00 Total 1879.00

Material balance of Ramipril Stage-2



In Kg Stage-1 510.00 Ramipril (Pure) 500.00 Ethanol 650.00 Ethanol recovery 618.00 5% Pd/Activated carbon 10.00 Ethanol loss 32.00 Water 50.00 Effluent water 50.00 (Water-50) Spent 5% Pd/Activated

carbon 10.00

Organic residue 10.00 Total 1220.00 Total 1220.00



5. SERTRALINE HYDROCHLORIDE


Stage-1

4-(3, 4-dichlorophenyl)-3, 4-dihydro-N-methyl-1(2H)-naphthalenimine reacts with

Sodium boro hydride to give Stage-1 compound in presence of Ethyl acetate.

Stage-2

Stage-1 compound isomerism with D (-) Mandelic acid to give Stage -2 compound in presence Ethyl acetate.

Stage-3

Stage-2 compound reacts with Hydrochloric acid to give Sertraline hydrochloride

in presence of Di iso propyl alcohol.



SERTRALINE HYDROCHLORIDE

Route of synthesis:

Stage-1

[4-(3,4-Dichloro-phenyl)-3,4-dihydro-2H-naphthalen

-1-ylidene]-methyl-amineC17H15Cl2N

304.21

+ NaBH4

37.83

+ 2 NaOH

80.00

+ H2O Ethylacetate

18.02

C17H17Cl2N

306.22

[4-(3,4-Dichloro-phenyl)-1,2,3,4-tetrahydro-naphthalen

-1-yl]-methyl-amine

Na3BO3

127.78

+ 3 H2

6.05

Cl

NMe

Cl

Cl

HN

Cl

CH3

+



Stage-2

C17H17Cl2N

306.22

[4-(3,4-Dichloro-phenyl)-1,2,3,4-tetrahydro-naphthalen

-1-yl]-methyl-amine

Cl

HN

Cl

CH3

D(-) Mandelic acid

Ethylacetate

C17H17Cl2N

306.22

Sertraline

Cl

HN

Cl

CH3

Stage-3

Cl

HN

Cl

CH3

C17H17Cl2N

306.22

Sertraline

+ 2 HCl

72.92

DiisopropyalalcoholCl

HN

Cl

CH3

Sertraline hydrochloride

. HCl

C17H18Cl3N

342.69

+ NaOH

40.00

+ H2O

18.02

+ NaCl

58.44




Flow Chart:

4-(3,4-dichlorophenyl)-3,4-dihydro-N-methyl-1(2H)-naphthalenimineSodium boro hydrideSodium hydroxideEthyl acetate

Ethyl acetate Recovery

Stage-1D(-) Mandelic acidEthyl acetate

Ethyl acetate Recovery

Stage-1

Stage-2


Stage-3

Stage-2Hydrochloric acidSodium hydroxideDi iso propyl alcohol

Di iso propyl alcohol Recovery




Material Balance:

Material Balance of Sertraline Hydrochloride Stage-1

Batch Size: 500.0Kgs Name of the input Quantity


in Kg 4-(3,4-dichlorophenyl)-3,4-dihydro-N-methyl-1(2H)-naphthalenimine

448.00 Stage-1 450.00

Sodium boro hydride 55.75 Ethyl acetate Recovery 950.00 Sodium hydroxide 387.85 Ethyl acetate Loss 50.00 Ethyl acetate 1000.00 Inorganic waste 305.00 Sodium sulfate 305.00 (Sodium sulfate) Water 400.00 Effluent water 831.63 (water-373.45 ,Sodium borate-

188.18,Sodium hydroxide-270)

Process emission 8.90 (Hydrogen-8.90) Organic residue 1.07 Total 2596.60 Total 2596.60




in Kg Stage-1 450.00 Stage-2 447.00 D(-) Mandelic acid 250.00 Reuse and Recovery 250.00 Ethyl acetate 1000.00 (D(-) Mandelic acid) Sodium sulfate 305.00 Ethyl acetate Recovery 950.00 Water 100.00 Ethyl acetate Loss 50.00 Effluent water 100.00 (Water-100) Inorganic waste 305.00 (Sodium sulfate) Organic residue 3.00 Total 2105.00 Total 2105.00






in Kg Stage-2 447.00 Sertraline Hydrochloride 500.00 Hydrochloric acid 106.45 Di iso propyl alcohol Recovery 570.00 Sodium hydroxide 58.40 Di iso propyl alcohol Loss 30.00 Di iso propyl alcohol 600.00 Effluent water 596.90 Sodium carbonate 285.30 (water-200,Generated water-

26.3,Sodium chloride-85.30,Sodium carbonate-285.3)

Water 200.00 Organic residue 0.25 Total 1697.15 Total 1697.15



6. TERBINAFINE HYDROCHLORIDE

Process Description

Stage-1

Dimethyl – naphthalene-1-yl-amine reacts with 1-chloro-6, 6-Dimethyl Hept-2-ene-4-

Yne in presence of Toluene to give Stage-1 compound

Stage-2

Stage-1 compound reacts with Hydrochloric acid in presence of Isopropyl alcohol to

give Terbinafine Hydrochloride product.



TERBINAFINE HYDROCHLORIDE

Route of Synthesis

Stage-1

Toluene

NH3C CH3

Dimethyl-naphthalen-1-yl-amine

C12H13N

171.24

1-Chloro-6,6-Dimethyl Hept-2-ene-4-yne

H3C

H3C CH3

Cl

C9H13Cl

156.65

+

N

CH3H3C

CH3

CH3

TerbinafineC21H25N

291.43

+ KCl

+ 1/2K2CO3

Potassium carbonate

69.10

74.55

+ 1/2CO2

22.0

+ 1/2H2O

9.0



Stage-2

N

CH3H3C

CH3

CH3

Terbinafine

C21H25N

291.43

+ HCl

Hydrochloric acid

36.5

IPA

N

CH3H3CCH3

CH3

Terbinafine Hydrochloride

C21H26ClN

327.89

. HCl




Flow Chart

Stage-1

Stage-2


Toluene Rec

Dimethylnaphthalen -1-yl amine1-Chloro-6,6-dimethylhept-2-en-4-yneToluenePotassium carbonate

Stage-1Hydrochloric acidIsopropyl alcohol

Isopropyl alcohol Rec




Material Balance:

Material Balance of Terbinafine Hydrochloride Stage-1



in Kg Dimethylnaphthalen -1-yl amine 419.00 Stage-1 712.00 1-Chloro-6,6-dimethylhept-2-en-4-yne

383.30 Toluene Recovery 760.00

Toluene 800.00 Toluene Loss 40.00 Potassium carbonate 169.10 By-Products 182.45 Water 1000.00 (Potassium chloride) Effluent water 1022.05 (Water-1000, Generated water-22.05,) Process Emission 53.85 (Carbon dioxide) Organic Residue 1.05 (Organic impurities-6.9,Toluene-4) Total 2771.40 Total 2771.40

Material Balance of Terbinafine Hydrochloride Stage-2

Batch Size:800.0Kgs Name of the input Quantity


in Kg Stage-1 712.00 Terbinafine Hydrochloride 800.00 Hydrochloric acid 89.00 IPA Recovery 570.00 IPA 600.00 IPA Loss 30.00 Carbon & hyflow 5.00 Effluent water 630.00 Water 630.00 (Water-630) Spent carbon & hyflow 5.00 Organic residue 1.00 Total 2036.00 Total 2036.00



7. TRAMADOL HYDROCHLORIDE


Stage-1

Cyclohexane reacts with Dimethylaminehydrochloride and Formaldehyde to give Stage-1 compound in presence of Water

Stage-2

Stage-1 compound reacts with m-Bromoanisole and Hydrochloric acid to give Tramadolhydrochloride in presence of Water.



TRAMADOL HYDROCHLORIDE

Route of synthesis:

Stage-1

O

CyclohexanoneC6H10O

98.14

+ H C H

O

Formaldehyde

30.03

+

Dimethylamine.HCl

(CH2)2NHHCl

C2H6ClN

79.53

+ NaOH

40.00

O

NCH3

CH3

2-Dimethylaminomethyl-cyclohexanone(mannichbase)

C9H17NO155.24

+ NaCl

58.44

+ H2

2.02

+

32.00

O2



Stage-2

O

NCH3

CH3

2-Dimethylaminomethyl-cyclohexanone

C9H17NO

155.24

+

OMe

Br

m-BromoanisoleC7H7BrO

187.03

+ Mg

24.30

+ HCl

36.46

+ 2 H2O

36.03

NH3C CH3

OHMeO

. HCl


C16H26ClNO2

299.84

+ Mg(OH)2

58.32

+ HBr

80.91




Flow chart:

Stage-1

Stage-2

Tramadol Hydrochloride

Effluent water

CyclohexaneFormaldhydeDimethylamine .hydrochlorideSodium hydroxide

2-Dimethylaminomethyl-cyclohexanonem-BromoanisoleMagnesiumHydrochloric acidCarbon

Effluent water




Material Balance

Material balance of Tramadol Hydrochloride Stage-1



In Kg Cyclohexane 419.00 Stage-1(Mannich) 420.00 Formaldehyde 356.60 Methanol Recovery 885.00 Dimethylamine .hydrochloride 216.00 Methanol Loss 45.00 Sodium hydroxide 109.00 Effluent water 20588.40 Methanol 1000.00 (water-20430,Sodium

hydrochloride-158.4)

Water 20430.00 Process emission 92.20 (Hydrogen-5.5,Oxygen-86.7) Organic residue 500.00 (Organic impurities-430,

Methanol-70)

Total 22530.60 Total 22530.60

Material balance of Tramadol Hydrochloride Stage-2



In Kg 2-Dimethylaminomethyl-cyclohexanone

420.00 Tramadol Hydrochloride 500.00

m-Bromoanisole 603.00 Methanol Recovery 888.00 Magnesium 75.00 Methanol Loss 45.00 Hydrochloric acid 97.00 Effluent water 22053.00 Activated Carbon 25.00 (water-21902.7,Magnesium

hydroxide-150.3) 0

Methanol

1000.00 Process Emission 209.00

Water 22000.00 (Hydrogen bromide-135) 0 Spent Carbon 25.00 Organic residue 500.00 (Organic Impurities-

260,Methanol-67,isomer of Bromoanisole-173)

Total 24220.00 Total 24220.00



2.6 POLLUTION LOAD Pollution load and generation of waste per day from all the proposed products is given in below table 2.4

TABLE 2.4: CONSOLIDATED POLLUTION LOAD OF ALL PRODUCTS IN Kgs PER DAY QUANTITES

S.No Product Name Production

Capacity

Effluent Details Solid waste Details Emissions

Water Input

Water In Effluent

Inorganics

in water

Organics in

water TDS COD HTDS LTDS

Total Effluen

t

Organic

Inorganic

Spent carbo

n

Total solid waste

Process Fugitive

Kg/Month Kg/Day Kg/Day Kg/Day Kg/Day Kg/Day Kg/D

ay Kg/Day Kg/Day Kg/Day Kg/Da

y Kg/Day Kg/Day Kg/Day Kg/Day Kg/Day

1 Carvedilol 5000.00 233.33 233.33 16.67 0 16.67 0 183.33 66.67 250 0.4 166.67 6.67 173.74 15.00 45.00

2 Citalopram Hydrobromide 2000.00 166.67 169.67 1.67 0 1.67 0 88.00 83.33 171.33 0.4 0.00 0.83 1.23 0.00 6.33

3 Ketorolac Tromethamine 5000.00 14066.67 14066.67 43.67 0 43.67 0 6777.00 7333.

33 14110.

33 335.6

7 0.00 3.33 339.00 0.00 16.67

4 Ramipril 5000.00 50.00 57.38 0 0 0 0 0.00 57.38 57.38 3.95 0.00 0.00 3.95 36.71 20.67

5 Sertraline Hydrochloride 5000.00 233.33 233.25 247.83 0 247.83 0 447.74 33.33 481.07 1.44 203.33 0.00 204.77 2.97 43.33

6 Terbinafine Hydrochloride 4000.00 271.67 275.34 0 0 0 0 0.00 275.3

4 275.34 0.34 0.00 0.83 1.17 8.98 11.67

7 Tramadol Hydrochloride 5000.00 14143.33 14110.9 102.9 0 102.9 0 14213.80 0.00 14213.

8 333.3

3 0.00 8.33 341.66 100.40 0.00

Total (Worst combination of Any

two products) 10000.00 28210.00 28177.57 350.73 0.00 350.73 0 20990.80 7608.

67 28599.

47 669.0

0 370.00 15.00 1054.00 137.11 88.33

Production Capacity

Water Input TDS COD HTDS LTDS Total Effluent

Organic Residue

Inorganic Residue

Spent Carbon



2.6.1 PROPOSED WATER CONSUMPTION & WASTE WATER GENERATION DETAILS The Total water consumption for the proposed project is 79.71 KLD. Water consumption details are given in below Table. No.4. Water requirement will be met through Ground Water.

TABLE-2.5: PROPOSED WATER CONSUMPTION

DETAILS S.No Purpose Water consumption In KLD

1 Process 28.21 2 Washings 2.00 3 Boiler make up 26.00 4 Cooling towers make up 15.00 5 Scrubbing system 1.00 6 Domestic 3.50 7 Gardening 4.00

Total 79.71


ii) Proposed Waste Water Generation Details The total water requirement for proposed project is 79.71 KLD and total waste water

generated will be 40.00 KLD which is from process, floor & reactor washes, cooling

tower blow down, boiler blow down, scrubber, DM plant and domestic usage. The

effluent generation and its HTDS & LTDS effluent details are given below.

TABLE-2.6: PROPOSED EFFLUENT GENERATION

DETAILS

S. No Purpose Effluent In KLD

1 Process 28.60 2 Washings 2.00 3 Boiler Blow down 4.00 4 Cooling towers Blow down 2.00 5 Scrubbing system 1.00 6 Domestic 2.40

Total 40.00



TABLE-2.7: PROPOSED HTDS & LTDS EFFLUENT DETAILS

Unit HTDS KLD

LTDS KLD

Effluent Generation in KLD

Treatment Method

Process 21.00 7.60 28.60 HTDS effluent sent to ETP with MEE System LTDS effluents treated in ETP – RO Plant / RO Rejects to MEE System and RO permeate to reuse, Condensate from MEE to reuse and MEE residue to ATFD.




2.6.2 WASTE WATER CHARACTERISTICS: Estimated wastewater characteristics

*We are going to achieve zero discharge. 2.6.3. HAZARDOUS & SOLID WASTE GENERATION DETAILS The Hazardous & Solid waste generated and disposal methods from proposed

project are given below.

S. No Parameters Unit

Results Before

treatment After

treatment* 1. pH pH unit 8.5-9.0 7.0-7.5 2. HTDS mg/L >5000 <500-800 3. LTDS mg/L <5000 <300-500 4. COD mg/L 4000-4500 50-100 5. Oil & Grease mg/L 20-25 2.0-5.0



TABLE- 2.8: PROPOSED HAZARDOUS WASTE & SOLID WASTE GENERATION, DISPOSAL DETAILS


Quantity In










Solid Waste Details


2.7 POWER (ENERGY) REQUIREMENT

Power requirement for the proposed project will be 300 KVA and is supplied through

APSPDCL.

2.8 UTILITIES

TABLE 2.9: DETAILS OF PROPOSED UTILITIES

S. No Description Capacity Proposed

1 Coal fired boilers 6.0 TPH Proposed 2 DG Sets 250 KVA Proposed 3 Cooling Towers 1X1000TR Proposed

4 Thermo pack Boiler 2, 00,000 K. Cal / Hr. Proposed

5 Electricity supply from APSPDCL. 300 KVA Proposed Fuel

1 Indian Coal / Agro waste 15.0TPD 2 Diesel 40 Liters/Day



2.9 PROPOSED BOILERS & DG SETS:


fired boiler. The coal requirement will be met from government allocation or from

local authorized sources, and the company is proposing 2,00,000 K. Cal / Hr.

Thermo pack Boiler. Proposing a 250 KVA DG set for usage during the power

failures. The emissions details are presented in bellow Table No 2.10

TABLE- 2.10: EMISSION CHARACTERISTIC DETAILS OF BOILER



Type of Fuel -- Indian Coal/Agro waste Coal Consumption TPD 15.0 Ash Content % 47 Sulphur Content % 0.8 Nitrogen Content % 1.07 No. of Stacks No 1 Height of stack m 32 Diameter of Stack m 0.60 Temperature of Flue Gas oC 110 Velocity of Flue Gas m/s 8.50 Particulate Matter at outlet of Bag filter (Based on 115 mg/Nm3 at outlet)

gm/sec 0.62

Sulphur dioxide emission gm/sec 1.39 Oxides of Nitrogen emission

gm/sec 1.86

Pollution control equipment

- Cyclone separator followed by suitable pack

of Bag filters

TABLE- 2.11 STACK EMISSION DETAILS OF DG SETS

Capacity In KVA

Emission of SPM

in mg/Nm3



Stack dia. In m

Flue Gas

Temp. in OC

Stack Height in m

Flue gas Velocity

In m/sec.

250 KVA (Proposed)

58.0 24.0 30.0 0.30 250 10 18.24



TABLE- 2.12: STACK EMISSIONS DETAILS OF THERMOPACK BOILERS


(Proposed) Thermo pack Boiler Capacity

K. Cal / Hr. 2,00,000

Type of Fuel -- Agro waste / Coal Stack Temperature Before Air preheater

oC 250


oC 180

Combination Air Temperature

oC 120

Efficiency Increased By % 5 Stack Height m 9.0 Fuel Consumption per Day

TPD 2.0

Diameter m 0.5



2.10 DETAILS OF PROPOSED SOLVENTS INPUT, RECOVERY & LOSS A liquid substance capable of dissolving other substances; "the solvent does not change its state in forming a solution". Details of solvents given below in a table 2.13.

TABLE 2.13: DETAILS OF PROPOSED SOLVENT INPUT, RECOVERY & LOSS [PRODUCT WISE]


capacity Kg/Month

Solvent Name

Quantity in Kgs/Day

Solvent Input

Solvent Recovery

Solvent Loss

Solvent in waste water Solvent in Residue

Kgs/Day Kgs/Day Kgs/Day Kgs/Day Kgs/Day 1 Carvedilol 5000.00 Ethyl actetate 266.67 253.33 13.33 0.00 0.00

Toluene 333.33 316.67 16.67 0.00 0.00

THF 300.00 285.00 15.00 0.00 0.00

Total 900.00 855.00 45.00 0.00 0.00 2 Citalopram Hydrobromide 2000.00 Toluene 41.67 39.50 2.17 0.00 0.00

Acetone 83.33 79.17 2.50 0.00 0.00

Total 125.00 118.67 4.67 0.00 0.00 3 Ketorolac Tromethamine 5000.00 Acetone 666.67 586.67 30.00 0.00 50.00

Total 666.67 586.67 30.00 0.00 50.00 4 Ramipril 5000.00 Ethyl acetate 200.00 190.00 10.00 0.00 0.00

Ethanol 216.67 206.00 10.67 0.00 0.00

Total 416.67 396.00 20.67 0.00 0.00 5 Sertraline Hydrochloride 5000.00 Ethyl acetate 666.67 633.33 33.33 0.00 0.00

Diisopropyl

alcohol 200.00 190.00 10.00 0.00 0.00

Total 866.67 823.33 43.33 0.00 0.00 6 Terbinafine Hydrochloride 4000.00 Toluene 133.33 126.67 6.67 0.00 0.67

IPA 100.00 95.00 5.00 0.00 0.00

Total 233.33 221.67 11.67 0.00 0.67 7 Tramadol Hydrochloride 5000.00 Methanol 666.67 591.67 30.00 0.00 45.00

Total 666.67 591.67 30.00 0.00 45.00

Grand Total 10000.00 1766.67 1678.33 88.33 0.00 95.00



2.11 DETAILS OF EXPECTED PROCESS EMISSIONS.

Expected Air Environment (Expected Process Emissions Details):

Process emissions are HCl, HBr, CO2, H2 and O2 which is liberated from

manufacturing process of proposed products.

TABLE-2.14: EXPECTED PROCESS EMISSION DETAILS


Disposal Method





2.12 LIST OF THE RAW MATERIALS PRODUCT WISE

CARVEDILOL

S.No. Raw Material Used/ Batch in Kgs

Used/ Day in Kgs Source

1 9H-Carbazol-4-ol 226.00 75.33 Indigenous 2 (Chloromethyl) oxirane 114.00 38.00 Indigenous 3 Tetrahydrofuran 900.00 300.00 Indigenous 4 Toluene 1000.00 333.33 Indigenous 5 Sodium sulfate 500.00 166.67 Indigenous

6 (2-methoxy phenoxy)ethylamine 206.20 68.73 Indigenous

7 Ethyl acetate 800.00 266.67 Indigenous

8 Sodium chloride(washing) 50.00 16.67 Indigenous

9 Activated carbon 20.00 6.67 Indigenous




S. No Raw Material Used/ Batch in Kgs

Used/ Day in Kgs Source

1 5-Cyanophthalide 158.00 26.33 Indigenous 2 4-fluorophenylmagnesium

chloride 154.00

25.67 Indigenous

3 (Dimethylamino)propyl magnesium chloride

145.00 24.17

Indigenous

4 Hydrochloric acid 72.40 12.07 Indigenous 5 Toluene 250.00 41.67 Indigenous 6 Hydrogen bromide 80.00 13.33 Indigenous 7 Sulfuric acid 10.00 1.67 Indigenous 8 Acetone 500.00 83.33 Indigenous 9 Activated Carbon & Hyflow 5.00 0.83 Indigenous



Used/ Day in Kgs

Source

1 5-chloro-2-benzoylpyrrole 783.00 261.00 Indigenous 2 Methyl-gama-methoxy

butanonate 300.00

100.00 Indigenous

3 Sodium hydroxide 90.00 30.00 Indigenous 4 Acetone 2000.00 666.67 Indigenous 5 Tromethamine 458.00 152.67 Indigenous 6 Carbon & hyflow 10.00 3.33 Indigenous

RAMIPRIL

S.No Raw Material Used/ Batch in Kgs

Used/ Day in Kgs

Source

1 2-(1-carboxy-ethylamino)-4-phenyl-butyric acid ethylester

343.00

114.33

Indigenous

2 (cis,endo)-octahydro-cyclopenta[b]pyrrole-2(s)-carboxylic acid hydrochloride

236.00

78.67

Indigenous

3 Ethyl acetate 600.00 200.00 Indigenous 4 Triethylamine 600.00 200.00 Indigenous 5 Ethanol 650.00 216.67 Indigenous 6 5% Pd/Activated carbon 10.00 3.33 Indigenous





Used/ Day in Kgs

Source

1 4-(3,4-dichlorophenyl)-3,4-dihydro-N-methyl-1(2H)-naphthalenimine

448.00

149.33

Indigenous

2 Sodium boro hydride 55.75 18.58 Indigenous 3 Sodium hydroxide 446.25 148.75 Indigenous 4 Ethyl acetate 2000.00 666.67 Indigenous 5 Sodium sulfate 610.00 203.33 Indigenous 6 D(-) Mandelic acid 250.00 83.33 Indigenous 7 Hydrochloric acid 106.45 35.48 Indigenous 8 Di iso propyl alcohol 600.00 200.00 Indigenous 9 Sodium carbonate 285.30 95.10 Indigenous



Used/ Day in Kgs

Source

1 Dimethylnaphthalen -1-yl amine

419.00 69.83

Indigenous

2 1-Chloro-6,6-dimethylhept-2-en-4-yne

383.30 63.88

Indigenous

3 Toluene 800.00 133.33 Indigenous 4 Potassium carbonate 169.10 28.18 Indigenous 5 Hydrochloric acid 89.00 14.83 Indigenous 6 IPA 600.00 100.00 Indigenous 7 Carbon & hyflow 5.00 0.83 Indigenous



Used/ Day in Kgs

Source

1 Cyclohexane 419.00 139.67 Indigenous 2 Formaldehyde 356.60 118.87 Indigenous 3 Dimethylamine

.hydrochloride 216.00

72.00 Indigenous

4 Sodium hydroxide 109.00 36.33 Indigenous 5 Methanol 2000.00 666.67 Indigenous 6 m-Bromoanisole 603.00 201.00 Indigenous 7 Magnesium 75.00 25.00 Indigenous 8 Hydrochloric acid 97.00 32.33 Indigenous 9 Activated Carbon 25.00 8.33 Indigenous

DESCRIPTION OF THE ENVIRONMENT

CHAPTER -III

EIA Report Vensar Laboratories Pvt. Ltd.

Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter – III Page 1

CHAPTER-III

DESCRIPTION OF THE ENVIRONMENT

3.0 INTRODUCTION

The baseline environmental qualities of various environmental components like air,

noise, water,land, flora and fauna and socio-economic form an important and integral

part of any environmental study. The baseline data forms the basis for predicting

/assessing the environmental impacts of the proposed project. The baseline

environmental quality is assessed through field surveys within the impact zone as well

as secondary data for various components of the environment, viz. air, noise, water and

land and socio-economic.

Various environmental conditions exist in the area surrounding the project site, which

are liable to be affected due to the project activities, have been assessed quantitatively

as well as qualitatively. In order to assess the feasibility of the said project, a study

related to the present environment condition has been carried out by generating the

baseline data.

3.1 STUDY AREA Vensar Laboratories Pvt Ltd., proposed to establish new bulk drug and intermediate

manufacturing unit at Sy. No. 32, Tupakulagudem Village, Tallapudi Mandal, West

Godavari District, Andhra Pradesh. It is necessary for the environmental assessment

studies to establish baseline status for valued Environmental components, which are

likely to be affected because of the proposed activity.

Hence, it is imperative to study the existing environmental conditions not only to

establish the pre-project physical, biological, and socio-economic conditions, but also to

predict environmental impacts caused during the construction and operation phases of

the project.

3.2 STUDY PERIOD

The baseline data was collected during March 2016 in a study area covering 10 km

radial distance from the project site as per ToR. The Base Map showing 10 Km Radius

of the project site is shown in Figure 3.1



The ambient air quality, water quality, and soil quality status within the area forms the

baseline information over which the predicted impacts due to the proposed project can

be superimposed in order to obtain the post project scenario of the study area

environment.

3.3 Geological & Hydrogeological Environment

Scope and Methodology

In any given environment the occurrence and movement of ground water and its quality

and quantity is chiefly controlled and governed by many factors such as geographical

set-up, climate and rainfall conditions, hydrological features, topography, soil

characteristics, the nature and thickness of underlying frock formations and other

related aspects that prevail in an area. Therefore the study envisages indentifying the

existing ground water conditions comprising both quality and potential within the project

site and its neighborhood, relating the projected utilization for the production, identifying

the likely impacts on surface and ground water resources and indicating mitigation

measures. In order to accomplish the proposed objective of the study, the scope and

methodology adopted is as follows:

Collection of the relevant data contained in the EIA and EMP Reports, from the

reports and maps of Central Ground Water Board (CGWB) Geological Survey

of India (GSI), other Institutions and Departments.

Identify Inter- related and Inter – dependent key factors that play vital role in the

occurrence of ground water its quality and potential.

Identify surface water resources in the project site and its catchment area.

Assess the ground water resource potential in the catchment area of the project

site.

Bring out various events and processes that comprise the project activity.

Identify the site specific environmental issues and mitigation measures and

Compile a consolidated, comprehensive and meaningful report of the Project

site and its catchment area.

Initially the data and scientific information available in the EIA and EMP reports and

reports of Central Ground Water Board have been collected. Subsequently field

investigation was carried out to study surface rock outcrops, geological cross sections in

the road cuttings and open wells were observed. Inventory of wells representing the



entire watershed area was carried out. Hydrogeological data of about 10 wells was

collected. Water levels were recorded in the bore wells and Dug wells were observed to

be dry.

The inventoried well data showed that the depth to water level ranging between 4.0 -

14.96 m below ground level.

Information already available and the data collected during the survey is collated and

analyzed to comprehend the overall ground water situation in the area. An attempt is

made to predict the likely changes that could occur on account of the proposed bulk

drug manufacturing and certain mitigation measures have been indicated to avoid

adverse effect on the ground water environment.

3.3.1 Topography

The site is a part of pediplain shallow weathered and is a plain land sloping towards

South and East. The site is at an altitude of 74 m MSL. No major streams are passing

through the site. Drainage pattern observed is Dendritic to sub-dendritic.

3.3.2. Geology

The district is underlain by Archaean crystallines, Gondwanas, Deccan Traps, Tertiaries

and alluvial sediments. About 45% of the district is underlain by Gondwana formations,

40% is underlain by Alluvium and the rest is by Archaean crystalline rocks.

3.3.3 Hydrogeology

The proposed manufacturing unit is located on the divide portion of the catchment and

is over the run off zone. No major streams are passing through the site. The catchment

area of the proposed site is small and recharge conditions are moderate. However, the

buffer zone of 10Kms radius has good catchment and recharge potential with streams

and tanks of considerable storage potential.

All the stream courses are ephemeral in character and carry large volumes of storm

flows during rainy season and remain dry during non - monsoon season. The present

stage of ground water development in the district is 61% in non-command and 12% in

command area with overall stage of ground water development of 36%. All the mandals

are falling in safe category, contrary to 10 over exploited, 4 critical mandals during

2004-05. The stage of development is generally high in area occupied by



sedimentaries, while it is low in canal command areas, suggesting the need for judicious

exploitation of ground water resources in future. A drainage map of the area around the

proposed plant is shown in Figure 3.1.

The proposed area is categorized as Safe by the Groundwater department and scope

for development & stage of groundwater is limited. The site is feasible for groundwater

extraction for the proposed bulk drug manufacturing unit and also as the area falls

under safe area thrust should be on providing artificial recharge structures and

utilization of surface water tanks located nearby with due permission from the State

Government.



FIGURE 3.1 SHOWING DRAINAGE MAP OF THE STUDY AREA



3.3.4 Micrometeorology and Climate

The micrometeorological conditions at the project site will regulate the transport and

diffusion of air pollutants released into the atmosphere. The principle meteorological

variables are horizontal convective transport (average wind speed and direction),

vertical convective transport (atmospheric stability, mixing height) and topography of

the area.

The meteorological data recorded during the study period is used for interpretation of

the baseline information as well as input for air quality simulation models.

Meteorological data was collected for Month of March 2016. A meteorological station

was installed in the project site at about 10 m above the ground level. All care was

taken to see that the station is free from obstructions to free flow of winds. Wind

speed, wind direction, temperature and relative humidity data was collected daily on

hourly basis during the study period.

The wind rose diagram for the study area is shown in Figure 3.2. The analysis of the

average wind pattern shows predominant winds from SSW,NE, S & SSE with wind

frequencies of 17.9, 10.0,9.4 and 9.4 % respectively. The calm conditions were

prevailed for 23.50 % of the total time. Average wind speed 1.50m/s.

A. Temperature:

During the study period the minimum and maximum temperatures were recorded as

20.0 °C and 41.0°C respectively.

B. Relative Humidity:

During the study period the minimum and maximum relative humidity at project site,

was recorded from 32.0 % - 52.0 % respectively.

C. Rainfall

No rainfall is observed during the study period at project site. The normal annual

rainfall in the District is 1078.00 mm (Source: Central Ground Water Board).

D. Wind Direction and Wind Speed

The data on surface meteorological parameters (hourly average wind speed &

direction) in the study area were collected during March 2016 by installing automatic

weather monitoring station at project site. The sensors of this equipment were kept

at about 10 m above ground level with free exposure to the atmosphere. The data on



temperature as well relative humidity were also recorded simultaneously using a

data logger.

These were positioned considering wind speed, downward and upward direction.

The recording was on hourly basis for three months. Wind rose of sixteen sector

basis data was collected on 24 hourly bases.

The hourly wind speed and wind direction observations are computed and the wind

rose diagrams are presented in Figure 3.2. The Frequency Distribution Wind

Directions and Wind Speed are shown in Table 3.1. The following observations can

be made from the collected data;

Calm period is observed to be 23.50 % during the time of monitoring.

The predominant wind direction is SSW & NE.

Other than predominant wind directions wind was blowing in S &SSE.

Mostly the wind speeds are observed to be in the range of 0.5 - 2.1 m/sec, 2.1

-3.6 m/Sec, 3.6 – 5.7 m/sec , 5.7 – 8.8 m/sec & > 11.1 m/Sec with frequency

of distribution percentages ranges from 56.5, 16.5, 3.2 ,0.3,0 & 0.



TABLE 3.1: FREQUENCY DISTRIBUTION WIND DIRECTIONS AND WIND SPEED

S. No Directions Wind Classes (m/s) 0.5 - 2.1 2.1 - 3.6 3.6 - 5.7 5.7 - 8.8 8.8 - 11.1 > 11.1 Total (%)

1 N 348.75 - 11.25 0.8 0.1 0.0 0.0 0.0 0.0 0.9 2 NNE 11.25 - 33.75 0.9 0.0 0.0 0.0 0.0 0.0 0.9 3 NE 33.75 - 56.25 6.5 3.5 0.0 0.0 0.0 0.0 10.0 4 ENE 56.25 - 78.75 1.1 0.9 0.4 0.0 0.0 0.0 2.4 5 E 78.75 - 101.25 0.3 0.4 0.3 0.0 0.0 0.0 1.0 6 ESE 101.25 - 123.75 0.4 0.0 0.0 0.0 0.0 0.0 0.4 7 SE 123.75 - 146.25 0.5 0.1 0.0 0.0 0.0 0.0 0.6 8 SSE 146.25 - 168.75 6.7 2.6 0.1 0.0 0.0 0.0 9.4 9 S 168.75 - 191.25 7.4 1.9 0.1 0.0 0.0 0.0 9.4

10 SSW 191.25 - 213.75 11.2 4.4 2.2 0.1 0.0 0.0 17.9 11 SW 213.75 - 236.25 0.5 0.0 0.0 0.0 0.0 0.0 0.5 12 WSW 236.25 - 258.75 8.3 0.4 0.0 0.1 0.0 0.0 8.8 13 W 258.75 - 281.25 0.7 0.0 0.0 0.0 0.0 0.0 0.7 14 WNW 281.25 - 303.75 5.9 0.7 0.1 0.0 0.0 0.0 6.7 15 NW 303.75 - 326.25 5.0 1.2 0.0 0.1 0.0 0.0 6.3 16 NNW 326.25 - 348.75 0.3 0.3 0.0 0.0 0.0 0.0 0.6

Sub-Total 56.5 16.5 3.2 0.3 0.0 0.0 76.5 Calms 23.5 Missing/Incomplete 0.0

Total 100.0



FIGURE 3.2: WINDROSE DAIGRAM DURING MARCH 2016

Source: WRPLOT VIEW - Lakes Environmental Software



3.4 AIR ENVIRONMENT

The objective of the ambient air quality monitoring is to establish the baseline conditions

with respect to the study area of a 10 km radius around the project site. The sources of

pollution are industries, vehicular traffic, agricultural fields, unpaved roads and domestic

fuel burning etc.

The base line status of the ambient air quality will be assessed through scientifically

designed Ambient Air Quality Monitoring Network.

The selection of sampling locations in the air quality surveillance programme is based

on the following.

(a) Representation of project site.

(b) Representation of down wind direction.

(c) Representation of upwind direction.

(d) Representation of cross sectional distribution in the down wind direction.

(e) Representation of residential areas.

The ambient air quality monitoring was carried out in accordance with National Ambient

Air Quality Standards (NAAQS) of CPCB. Ambient Air Quality Monitoring (AAQM) was

carried out at six locations during the study period and the locations are shown in

Figure 3.3. The locations of the different stations with respect to its distance and

direction from project site are shown in Table 3.2.



TABLE 3.2: AMBIENT AIR QUALITY SAMPLING LOCATIONS

S. No. Code Name of Sampling Location

Distance (KMs) w.r.t Project

Direction w.r.t Project

1 A1 Plant Site -- -- 2 A2 Gopavaram 1.43 NNE 3 A3 Ramapalem 3.84 NW 4 A4 Bhimolu 1.98 SW 5 A5 Surayyapeta 2.31 SE 6 A6 Tupakulagudem 5.88 E

The monitoring was carried out for one month i.e March 2016 at a frequency of twice a

week at each station adopting a continuous 24- hour schedule.

The following parameters were monitored in the study area :

Particulate Matter (PM10)

Particulate Matter (PM2.5)

Sulphur Dioxide (SO2)

Oxides of Nitrogen (NOx)

Carbon Monoxide (CO)

Ammonia (NH3)

Volatile Organic Compounds (VOC)



FIGURE 3.3: AMBIENT AIR QUALITY SAMPLING LOCATIONS MAP



3.4.1. National Ambient Air Quality Standards (NAAQS)

National Ambient Air Quality Standards, 2009 for the notified Industrial, Residential,

Rural and Other Areas as well as Sensitive Areas are presented in table below. The

state has not promulgated separate Ambient Air Quality Standards.

TABLE 3.3: NATIONAL AMBIENT AIR QUALITY STANDARDS

S.No

Pollutant

Time Weighted Average

Concentration in Ambient Air

Industrial, Residential, Rural and

Other Area

Ecological Sensitive

Area (Notified by

Central Government)

Methods of

Measurement

1 Sulphur Dioxide (SO2) µg/m3

Annual* 24 Hours**

50

80

20

80

Improved west and Gaeke Ultraviolet fluorescence

2 Oxides of Nitrogen as NO2 µg/m3

Annual* 24 Hours**

40

80

30

80

Modified Jacob & Hochheiser (Nn-Arsenite) Chemiluminescence

3

Particulate matter (size Less than 10µm) µg/m3

Annual* 24 Hours**

60

100

60

100

Gravimetic TOEM Beta Attenuation

4

Particulate matter (size less than 2.5 µm) µg/m3

Annual* 24 Hours**

40

60

40

60

Gravimetic TOEM Beta Attenuation

5 Ozone µg/m3

8 hours** 1 hour**

100

180

100

180

UV Photometric Chemilminescence Chemical Method

6 Lead (Pb) µg/m3

Annual* 24 hours**

0.50

1.0

0.50

1.0

AAS /ICP method after sampling on EPM 2000 or equivalent filter paper ED-XRF using Teflon filter.

7 Carbon Monooxide mg/m3

8 hours** 1 hour**

02

04

02

04

Non Dispersive Infra Red(NDIR) Spectroscopy

8 Ammonia (NH3) µg/m3

Annual*

100

100

Chemilminescence Indophenols blue



24 hours**

400 400 method

9 Benzene µg/m3 Annual*

05

05

Gas Chromatography based continuous analyzer Absorption and Desorption followed by GC analysis

10

Benzo(a) pyrene (BaP)- Particulate Phase only ng/m3

Annual* 01 01 Solvent extraction followed by HPLC/GC analysis

11 Arsenic ng/m3 Annual* 06 06

AAS/ICP method after sampling on EPM 2000 or equivalent filter paper

12 Nickel ng/m3 Annual* 20 20

AAS/ICP method after sampling on EPM 2000 or equivalent filter paper

G.S.No.826 (E) dated 16th November, 2009. Vide letter no. F. No. Q-15017/43/2007-CPW.

*Average Arithmetic mean of minimum 104 measurements in a year taken for a week 24

hourly at uniform interval.

**24 hourly/8 hourly values should meet 98 percent of the time in a year.

3.4.2. Ambient Air Quality Data (AAQ)

The Maximum, Minimum & 98th percentile values for all the sampling are shown in

Table 3.4. The location wise monitored Ambient Air Quality details are presented in

Table 3.5 to Table 3.12.

1. Particulate Matter (PM10)

Particulate Matter (PM10) monitored in the study area showed 98th percentile values

in the range of 57.86 – 68.32 μg/ m3. Highest value of 68.32 μg/ m3 was recorded

at Gopavaram.



2. Particulate Matter (PM2.5)

Particulate Matter (PM2.5) monitored in the study area showed 98th percentile values

in the range of 21.97 – 34.87 μg/m3. Highest value of 34.87 μg/ m3 was recorded at

Ramapalem.

3. Sulphur Dioxide (SO2)

98th percentile value of Sulphur dioxide in the study area from the monitored data

was in the range of 7.14 – 14.05 μg/ m3. Maximum value of Sulpur dioxide of 14.05

μg/ m3 obtained near the sampling locations of Tupakulagudem.

4. Oxides of Nitrogen (NOx) Ambient air quality status monitored for oxides of nitrogen in the study area were in

the range with 98th percentile values between 18.89 – 23.11 μg/ m3. A maximum

value of 23.11 μg/ m3 was prevailing at the time of sampling at Tupakulagudem.

5. Carbon Monoxides(CO)

98th percentile value of Carbon Monoxide in the study area from the monitored data

was in the range of 0.51 – 0.71 mg/ m3. Maximum value of Carbon Monoxide of

0.71 mg/ m3 obtained near the sampling locations at Ramapalem.

6. Ammonia (NH3) 98th percentile value of Ammonia in the study area from the monitored data was in

the range of 23.0 – 29.20 mg/ m3. Maximum value of Ammonia of 29.20 mg/ m3

obtained near the sampling locations at Gopavaram.



TABLE 3.4: THE MAXIMUM, MINIMUM & 98TH PERCENTILE VALUES FOR ALL THE SAMPLING LOCATIONS

* VOC Values monitored was Below Detectable Limit i.e 1 ppm

Code Name of

Sampling Location

PM10(µg/m3) PM2.5(µg/m3) SO2(µg/m3) NOX(µg/m3) CO (mg/m3) NH3( µg/m3)

Min Max 98th Min Max 98th Min Max 98th Min Max 98th Min Max 98th Min Max 98th

A1 Plant Site 59.40 66.90 66.75 24.20 28.90 28.72 11.9 13.5 13.5 18.10 22.60 22.46 0.45 0.53 0.53 15.20 23.10 23.00

A2 Gopavaram 62.15 68.50 68.32 19.50 25.20 25.16 8.80 11.50 11.40 16.50 18.90 18.89 0.43 0.56 0.56 21.60 29.30 29.20

A3 Ramapalem 48.80 61.80 61.58 23.14 35.14 34.87 11.20 13.20 13.14 18.12 23.11 23.11 0.44 0.72 0.71 20.40 28.70 28.52

A4 Bhimolu 52.00 58.00 57.86 17.90 26.00 25.97 5.50 7.20 7.14 16.80 19.50 19.40 0.44 0.57 0.56 22.10 29.20 29.07

A5 Surayyapeta 55.40 64.30 64.29 16.90 22.10 21.97 9.90 12.40 12.32 16.90 22.40 22.06 0.39 0.54 0.54 18.90 25.60 25.42

A6 Tupakulagudem 60.21 68.10 68.07 23.14 31.40 31.27 9.50 14.20 14.05 18.12 23.11 23.11 0.44 0.59 0.59 22.60 29.20 29.10

CPCB Standards’ 100.00 60.00 80.00 80.00 2.00 400



TABLE 3.5: AMBIENT AIR QUALITY, STATION: A1 (PLANT SITE)

Date Week PM 10 PM 2.5 SO2 NOX CO NH3 05.03.2016 1 64.9 24.2 13.2 22.6 0.49 15.2 06.03.2016 1 63.2 25.6 12.4 21.0 0.46 18.4 11.03.2016 2 59.4 27.6 11.9 19.4 0.50 20.3 12.03.2016 2 61.1 26.8 12.8 18.1 0.52 19.8 20.03.2016 3 64.5 24.6 12.9 21.6 0.49 22.4 21.03.2016 3 65.8 25.8 13.5 20.3 0.50 23.1 28.03.2016 4 65.7 28.9 12.6 19.4 0.53 20.5 29.03.2016 4 66.9 27.4 13.4 20.7 0.45 21.6

Minimum 59.40 24.20 11.9 18.10 0.45 15.20 Maximum 66.90 28.90 13.5 22.60 0.53 23.10 Average 63.94 26.36 12.8 20.39 0.49 20.16 98 Percentile 66.75 28.72 13.5 22.46 0.53 23.00

TABLE 3.6: AMBIENT AIR QUALITY, STATION: A2 (GOPAVARAM)





TABLE 3.7: AMBIENT AIR QUALITY, STATION: A3 (RAMAPALEM)



TABLE 3.8: AMBIENT AIR QUALITY, STATION: A4 (BHIMOLU)

Date Week PM 10 PM 2.5 SO2 NOX CO NH3 02.03.2016 1 52.0 19.5 6.2 18.2 0.48 28.3 03.03.2016 1 58.0 17.9 6.8 17.4 0.49 29.2 08.03.2016 2 55.2 19.2 7.2 18.8 0.52 26.7 09.03.2016 2 54.0 18.8 6.3 16.8 0.49 25.9 16.03.2016 3 56.2 26.0 6.7 18.1 0.47 27.3 17.03.2016 3 54.2 25.8 5.8 19.5 0.44 26.1 24.03.2016 4 52.0 25.7 5.5 18.7 0.52 24.6 25.03.2016 4 57.0 24.4 6.8 17.6 0.57 22.1 Minimum 52.00 17.90 5.50 16.80 0.44 22.10 Maximum 58.00 26.00 7.20 19.50 0.57 29.20 Average 54.83 22.16 6.41 18.14 0.50 26.28 98 Percentile 57.86 25.97 7.14 19.40 0.56 29.07



TABLE 3.9: AMBIENT AIR QUALITY, STATION: A5 (SURAYYAPETA)



TABLE 3.10: AMBIENT AIR QUALITY, STATION: A6 (TUPAKULAGUDEM)

Date PM 10 PM 2.5 SO2 NOX CO NH3 05.03.2016 1 60.2 28.2 12.4 19.5 0.44 22.6 06.03.2016 1 62.2 26.1 14.2 19.7 0.58 23.7 11.03.2016 2 65.2 23.8 10.5 18.1 0.51 28.5 12.03.2016 2 63.8 23.1 10.8 18.7 0.59 29.2 20.03.2016 3 67.9 30.5 9.5 23.1 0.54 26.3 21.03.2016 3 64.5 31.4 9.8 23.1 0.51 27.4 28.03.2016 4 66.7 29.5 11.6 20.3 0.55 25.4 29.03.2016 4 68.1 25.6 13.1 21.2 0.58 24.3


3.5 WATER ENVIRONMENT

Water sampling and subsequent analysis were carried out to determine both the

groundwater and surface water quality of the study area.

Ground water occurs under unconfined, semi to confined conditions in different

formations of the area.

six bore wells and two dug wells were inventoried to assess the groundwater conditions.

The depth to water levels was found to be 4.0 - 14.96 m bgl. The quality of water is



found to be potable. Ground Water development is limited in alluvium and in general the

deeper zones are brackish to saline in nature. In general, the ground water is suitable

for drinking and irrigation purposes in crystallines, sedimentaries while that occurring in

alluvium the water is not suitable purpose and irrigation purpose under ordinary

conditions. The water table gradient is steep in northern part and is very gentle in

southern part and the direction of ground water flow is towards southeast.

The baseline water quality status in the region is established by analyzing surface water

and ground water. Water requirement at site would be met through ground water.

3.5.1 Methodology for Water Quality Monitoring

Ground water samples at six locations and surface water samples at Four locations

were collected from the study area. The wastewater samples are collected at inlet and

out let areas. These samples were analyzed for physico - chemical parameters to

ascertain the baseline status in the existing surface water and ground water bodies.

Samples were collected during the study period and analyzed as per standard methods

of water and wastewater analysis (APHA). The details of surface and ground water

sampling locations are given in Table 3.13 and sampling locations of ground water

quality and surface quality monitoring are shown in Figure 3.4. The physic - chemical

characteristics of the ground water samples and surface water samples are presented

in the Tables 3.12 to Tables 3.14.



TABLE 3.11: SURFACE AND GROUND WATER SAMPLING LOCATIONS

S

No. Code Name of Sampling Location

Distance (km)

w.r.t Project

Direction

w.r.t Project

Ground Water Sampling Locations

1 GW1 Near Plant Site -- --

2 GW2 Gopavaram 1.43 NNE

3 GW3 Ramapalem 3.84 NW

4 GW4 Bhimolu 1.98 SW

5 GW5 Annadevarapeta 5.49 SE

6 GW6 Tupakulagudem 5.8 E

Surface Water Sampling Locations

1 SW1 Tank near Bhimolu 2.65 SW

2 SW2 Godavari River Downstream 8.70 SE

3 SW3 Godavari River Upstream 8.31 NE

4 SW4 Tadipudi lift canal 1.50 S



FIGURE 3.4: GROUND & SURFACE WATER SAMPLING LOCATIONS MAP



A. Summary of Groundwater Samples within 10 Km Radius

pH of the ground water samples collected was in the range between 7.08 – 8.29

Total dissolved solids in the samples were in the range between 610.5 – 1325.0

mg/l.

Total hardness was found to vary between 285.0 – 600.00 mg/l.

Chlorides concentration was found to vary between 94.9 – 419.9mg/l.

Fluoride concentration was found to below <0.5 mg/l

Sulphates concentration was found to vary between 35.22 – 73.20 mg/l.

Ground water samples collected from six locations within 10 km radius from the plant

site & analyzed as per standard methods of water and wastewater analysis (APHA).

B. Summary of Surface Water Samples within 10 km Radius:

pH of the water samples collected was in the range between 7.09 - 7.66.

Total dissolved solids in the samples were in the range between 297.00 – 606.0

mg/l.

Total hardness was found to be in the range of 203 – 379 mg/l.

Chlorides concentration was found to vary between 79 – 139 mg/l.

Fluoride concentration was found to be <0.5 mg/l.

Sulphates concentration was found to vary between 22.4 – 74.20 mg/l.

Heavy metal concentration in all the samples was found to be well within the

limits.

Surface Water samples collected at 4 locations within 10 km radius from the plant and

water quality of the study area is found to be above limits for some parameters.



TABLE 3.12 GROUNDWATER QUALITY IN THE STUDY AREA

S. No Parameter Method Unit GW 1 GW 2 GW 3 IS 10,500 Limits

Acceptable Permissible 1 pH APHA 22nd Edition 4500 H+ B -- 7.45 8.29 7.62 6.5-8.5 No Relaxation 2 Color APHA 22nd Edition 2120 B CU < 1.0 <1.0 < 1.0 5 15

3 Total Dissolved Solids APHA 22nd Edition 2540 C mg/l 640 1325.0 610.5 500 2000

4 Total Alkalinity (as CaCO3) APHA 22nd Edition 2320 B mg/l 315 340.0 255 200 600

5 Total Hardness (as CaCO3) APHA 22nd Edition 2340 C mg/l 380 590.0 285 200 600

6 Calcium (as Ca ) APHA 22nd Edition 3500 Ca B mg/l 137.5 145.34 85.5 75 200 7 Magnesium (as Mg) APHA 22nd Edition 3500-Mg B mg/l 20.04 62.04 33.62 30 100 8 Sulphate (as SO4) APHA 22nd Edition 4500 SO4 D mg/l 73.2 69.0 58.65 200 400 9 Chloride (as Cl) APHA 22nd Edition 4500 Cl- C mg/l 119.9 419.9 229.4 250 1000

10 Lead as Pb APHA 22nd Edition 3111B mg/l < 0.001 < 0.001 < 0.001 0.01 No Relaxation

11 Cadmium as Cd APHA 22nd Edition 3111B mg/l < 0.001 <0.001 < 0.001 0.003 No Relaxation

12 Total Chromium as Cr APHA 22nd Edition 3111B mg/l < 0.05 <0.05 < 0.05 0.05 No Relaxation 13 Copper as Cu APHA 22nd Edition 3111B mg/l < 0.01 < 0.01 < 0.01 0.05 1.5 14 Zinc as Zn APHA 22nd Edition 3111B mg/l < 0.5 < 0.5 < 0.5 5 15 15 Nickel as Ni APHA 22nd Edition 3111B mg/l < 0.01 <0.01 < 0.01 0.02 No Relaxation 16 Fluorides as F APHA 22nd Edition 4500 F- D mg/l <0.5 <0.5 <0.5 1 1.5 17 Aluminium as Al APHA 22nd Edition 3500 Al B mg/l < 0.03 <0.03 < 0.03 0.03 0.2 18 Boron as B APHA 22nd Edition 4500 B B mg/l <0.2 <0.2 <0.2 0.5 1 19 Manganese as Mn APHA 22nd Edition 3111B mg/l <0.02 <0.02 <0.02 0.1 0.3 20 Iron as Fe APHA 22nd Edition 3500 Fe B mg/l < 0.1 2.49 5.22 0.3 No Relaxation 21 Nitrate Nitrogen APHA 22nd Edition 4500 NO3 B mg/l 11.6 2.25 1.54 45 No Relaxation 22 Sodium as Na APHA 22nd Edition 3500 Na B mg/l 85.5 140.5 125.0 -- -- 23 Potassium as K APHA 22nd Edition 3500 K B mg/l < 5.0 < 5.0 < 5.0 -- -- 24 Odour APHA 22nd Edition 2150 B -- Agreeable Agreeable Agreeable -- --

25 Electrical Conductivity APHA 22nd Edition 2510 B μmho/cm 1050 2054 1050 -- --

26 Phosphorus as P APHA 22nd Edition 4500 P C mg/l <0.1 1.60 0.52 -- --



TABLE 3.13: GROUNDWATER QUALITY IN THE STUDY AREA

S. No Parameter Method Unit GW4 GW 5 GW6 IS 10,500 Limits

Acceptable Permissible 1 pH APHA 22nd Edition 4500 H+ B -- 7.08 8.23 7.45 6.5-8.5 No Relaxation 2 Color APHA 22nd Edition 2120 B CU <1.0 <1.0 <1.0 5 15

3 Total Dissolved Solids APHA 22nd Edition 2540 C mg/l 795.0 1289.0 650.0 500 2000

4 Total Alkalinity (as CaCO3) APHA 22nd Edition 2320 B mg/l 205 325.0 140 200 600

5 Total Hardness (as CaCO3) APHA 22nd Edition 2340 C mg/l 330 600.0 290 200 600

6 Calcium (as Ca ) APHA 22nd Edition 3500 Ca B mg/l 95.53 140.28 78.04 75 200 7 Magnesium (as Mg) APHA 22nd Edition 3500-Mg B mg/l 28.06 60.75 29.06 30 100 8 Sulphate (as SO4) APHA 22nd Edition 4500 SO4 D mg/l 40.50 65.16 35.22 200 400 9 Chloride (as Cl) APHA 22nd Edition 4500 Cl- C mg/l 129.9 399.6 94.9 250 1000

10 Lead as Pb APHA 22nd Edition 3111B mg/l < 0.001 < 0.001 < 0.001 0.01 No Relaxation

11 Cadmium as Cd APHA 22nd Edition 3111B mg/l < 0.001 <0.001 < 0.001 0.003 No Relaxation

12 Total Chromium as Cr APHA 22nd Edition 3111B mg/l < 0.05 <0.05 < 0.05 0.05 No Relaxation 13 Copper as Cu APHA 22nd Edition 3111B mg/l < 0.01 < 0.01 < 0.01 0.05 1.5 14 Zinc as Zn APHA 22nd Edition 3111B mg/l < 0.5 < 0.5 < 0.5 5 15 15 Nickel as Ni APHA 22nd Edition 3111B mg/l < 0.01 <0.01 < 0.01 0.02 No Relaxation 16 Fluorides as F APHA 22nd Edition 4500 F- D mg/l <0.5 <0.5 <0.5 1 1.5 17 Aluminium as Al APHA 22nd Edition 3500 Al B mg/l < 0.03 <0.03 < 0.03 0.03 0.2 18 Boron as B APHA 22nd Edition 4500 B B mg/l <0.2 <0.2 <0.2 0.5 1 19 Manganese as Mn APHA 22nd Edition 3111B mg/l < 0.02 <0.02 < 0.02 0.1 0.3 20 Iron as Fe APHA 22nd Edition 3500 Fe B mg/l 3.35 2.43 2.91 0.3 No Relaxation 21 Nitrate Nitrogen APHA 22nd Edition 4500 NO3 B mg/l 1.14 2.41 1.02 45 No Relaxation 22 Sodium as Na APHA 22nd Edition 3500 Na B mg/l 45.55 110.3 35.20 -- -- 23 Potassium as K APHA 22nd Edition 3500 K B mg/l < 5.0 < 5.0 < 5.0 -- -- 24 Odour APHA 22nd Edition 2150 B -- Agreeable Agreeable Agreeable -- --

25 Electrical Conductivity APHA 22nd Edition 2510 B μmho/cm 1250 1733 975 -- --

26 Phosphorus as P APHA 22nd Edition 4500 P C mg/l 0.50 1.67 0.42 -- --



TABLE 3.14: SURFACE WATER QUALITY IN THE STUDY AREA S. No Parameter Method Unit SW 1 SW 2 SW 3 SW 4

1 pH APHA 22nd Edition 4500 H+ B -- 7.66 7.49 7.45 7.09 2 Color APHA 22nd Edition 2120 B CU <1.0 < 1.0 < 1.0 <1.0 3 Turbidity APHA 22nd Edition 2130 B NTU 3.8 2.8 2.3 4.8 4 Total Dissolved Solids APHA 22nd Edition 2540 C mg/l 600.2 432 606 297 5 Total Alkalinity (as CaCO3) APHA 22nd Edition 2320 B mg/l 294 180 310 138 6 Total Hardness (as CaCO3) APHA 22nd Edition 2340 C mg/l 367 276 379 203 7 Calcium (as Ca ) APHA 22nd Edition 3500 Ca B mg/l 82 68 104 44 8 Magnesium (as Mg) APHA 22nd Edition 3500-Mg B mg/l 42.5 29 35 23 9 Sulphate (as SO4) APHA 22nd Edition 4500 SO4 D mg/l 64.2 36.8 74.2 22.4 10 Chloride (as Cl) APHA 22nd Edition 4500 Cl- C mg/l 139 130 121 79 11 Lead as Pb APHA 22nd Edition 3111B mg/l < 0.05 < 0.05 < 0.05 < 0.05 12 Cadmium as Cd APHA 22nd Edition 3111B mg/l < 0.01 < 0.01 < 0.01 < 0.01 13 Total Chromium as Cr APHA 22nd Edition 3111B mg/l <0.05 < 0.05 < 0.05 <0.05 14 Copper as Cu APHA 22nd Edition 3111B mg/l < 0.01 < 0.01 < 0.01 < 0.01 15 Zinc as Zn APHA 22nd Edition 3111B mg/l < 0.5 < 0.5 < 0.5 < 0.5 16 Nickel as Ni APHA 22nd Edition 3111B mg/l < 0.5 < 0.5 < 0.5 < 0.5 17 Fluorides as F APHA 22nd Edition 4500 F- D mg/l < 0.5 < 0.5 < 0.5 < 0.5 18 Aluminium as Al APHA 22nd Edition 3500 Al B mg/l < 0.03 < 0.03 < 0.03 < 0.03 19 Boron as B APHA 22nd Edition 4500 B B mg/l < 1.0 < 1.0 < 1.0 < 1.0 20 Manganese as Mn APHA 22nd Edition 3111B mg/l <0.05 < 0.05 < 0.05 <0.05 21 Iron as Fe APHA 22nd Edition 3500 Fe B mg/l < 0.1 < 0.1 < 0.1 < 0.1 22 Nitrate Nitrogen APHA 22nd Edition 4500 NO3 B mg/l 4.90 2.4 9.2 8.4 23 Chemical Oxygen Demand APHA 22nd Edition 5220 B mg/l 134.3 243.8 148.2 124.5 24 BOD(3day’s at 27oC) IS 3025 (Part – 44) 2009 mg/l 43.6 79.2 49.3 42.2 25 Sodium as Na APHA 22nd Edition 3500 Na B mg/l 88.6 55.0 74.0 34.5 26 Potassium as K APHA 22nd Edition 3500 K B mg/l 2.4 3.2 4.6 2.8 27 Total Suspended Solids APHA 22nd Edition 2540 D mg/l 25.8 18.4 16.8 12.4 28 Oil and grease APHA 22nd Edition 5520 B mg/l <5.0 <5.0 <5.0 <5.0 29 Electrical Conductivity APHA 22nd Edition 2510 B μmho/cm 1175.96 843.6 1161.6 591 30 Phosphorus as P APHA 22nd Edition 4500 P C mg/l <1.0 <1.0 <1.0 <1.0 31 Total Coliform IS 1622 MPN/100 ml 44.2 28.2 28.9 34.3 32 Feacal Coliforms IS 1622 MPN/100 ml Absent Absent Absent Absent



3.6. NOISE ENVIRONMENT

Noise, often defined as unwanted sound, interferes with speech communication, causes

annoyance, distracts from work, and disturbs sleep thus deteriorating quality of human

environment. Noise levels in the study area have therefore been measured, at selected

points, to provide the baseline data to describe the existing situation.

Measured noise levels displayed as a function of time provides a useful scheme for

describing the acoustical climate of a community. Noise levels records at each station

with a time interval of about 30 minutes are computed for equivalent noise levels.

Equivalent noise level is a single number descriptor for describing time varying noise

levels. The equivalent noise level is defined as mathematically.

10Log1/ TΣ (10Ln/10)

Where L = sound pressure level a function of time dB (A) & T = Time interval of

observations

Noise levels during the night time generally drop, therefore to compute Equivalent noise

levels for the night time, noise levels are increased by 10 dB (A) as the night time high

noise levels are judged more annoying compared to the day time.

Noise levels at a particular station are represented as Day- Night equivalent (Ldn). Day-

Night equivalent is the single number index designed to rate environmental noise on

daily /24 hourly basis. Mathematically Ldn is given by

Ldn = 10 log {1/24 (15 x 10(Ld/10) + 9 x 10 (Ln + 10)/10)}

Where

Ld = A weighed equivalent for day time period (6 am to 10 pm)

Ln = A weighed equivalent for night time period (10 pm to 6 am)



3.6.1 Noise Monitoring Stations

In order to assess the noise levels in the study area, monitoring was carried out at six

different locations within 10 km radius of the study area. The noise monitoring locations

are shown in figure 3.5 and distances & directions of monitoring location mentioned in

Table 3.16. Noise levels were recorded and computed for equivalent noise levels for

day-equivalent, night-equivalent & day-night equivalent.

Sound Pressure Levels (SPL) measurements were recorded at six locations. The

readings were taken for every hour for 24-hrs. The day noise levels have been

monitored during 6 am to 10 pm and night noise levels during 10 pm to 6 am at all the

locations covered in the study area.

The noise recording stations and the summary of the minimum, maximum, day -

equivalent, night - equivalent and day-night equivalent values computed for various

location in the study area is given in Table 3.16.

TABLE 3.15: NOISE MONITORING LOCATIONS

S No. Code Name of Sampling Location

Distance (km) w.r.t Project


1. N1 Plant Site -- -- 2. N2 Gopavaram 1.43 NNE 3. N3 Ramapalem 3.84 NW 4. N4 Bhimolu 1.98 SW 5. N5 Surayyapeta 2.31 SE 6. N6 Tupakulagudem 5.88 E



FIGURE 3.5: NOISE SAMPLING LOCATIONS MAP



TABLE 3.16: AMBIENT NOISE LEVELS WITHIN STUDY AREA

S.No

Name of the place

Day Time

In Leq

Night Time

In Leq

CPCB NORMS

(Day time)

CPCB NORMS

(Night time) 1. Plant Site 47.9 38.2

75dB (A) 70dB (A)

2. Gopavaram 47.6 38.1 3. Ramapalem 41.9 35.3

4. Bhimolu 45.0 35.0

5. Surayyapeta 43.7 37.0

6. Tupakulagudem 45.2 33.6 Day time Noise Levels (Lday)

The day time noise levels at all the locations ranged from 41.9 dB(A) to 47.9 dB(A)

with the minimum recorded at Ramapalem (N3) and the maximum at Plant Site

(N1).

Night time Noise Levels (Lnight)

The night time noise levels ranged from 33.6 dB (A) to 38.2 dB (A), with the

minimum value recorded at Tupakulagudem (N6) and the Maximum value at Plant

Site (N1).

It is observed that the noise values obtained were within the prescribed ambient

noise Quality Standards with respect to Noise.

3.6.2 TRAFFIC STUDY

Anthropogenic emissions not only contribute to the green house effect but also

participate in the reaction that results in photochemical oxidants. The effect of

photochemical oxidants is well known for forming smog particularly in the urban

areas.Among the anthropogenic sources of pollutants forming the green house

gases, burning of fossil fuels constitute a major source. State Highway mobile

sources that contribute significantly to poor quality have been regulated for the past

two decades in countries like India. The absence of regulation in developing

countries has caused a global concern regarding potential environmental damage on

a larger scale.

The traffic survey was carried out on the SH-42 (Chityala to Tallapudi Road) which is

SE from the plant. Vehicular traffic counts were performed on either side of the

studied roads to provide background values of traffic density, and correlate such



data to the levels of air pollution along the road. Vehicular traffic on these roads

included heavy vehicle, light vehicle, three wheelers, and two wheelers. The

additional traffic due to the project would also occur in this time duration only. From

the study it is observed that there is no major impact on traffic due to the proposed

project. A summary of the data is presented in Table 3.17



TABLE 3.17 : TRAFFIC STUDY AT SH -42 (CHITYALA TO TALLAPUDI ROAD)

S.No Time Two Wheelers

2 Wheeler @ 0.75

PCU

Three Wheeler

3 Wheeler

@ 1.2 PCU

Passenger cars

Passenger cars @ 1

PCU Heavy

vehicles

Heavy Vehicles

@3.7 PCU

Total vehicles

Total vehicles

PCU

1 06-07 am 12 9 4 5 4 4 3 11 23 29 2 07-08 am 19 14 8 10 6 6 6 22 39 52 3 08-09 am 23 17 10 12 9 9 9 33 51 72 4 09-10 am 25 19 14 17 12 12 8 30 59 77 5 10-11 am 44 33 15 18 18 18 9 33 86 102 6 11-12 pm 36 27 11 13 20 20 4 15 71 75 7 12-01 pm 40 30 8 10 14 14 5 19 67 72 8 01-02 pm 24 18 9 11 10 10 6 22 49 61 9 02-03 pm 29 22 7 8 16 16 5 19 57 65

10 03-04 pm 33 25 9 11 9 9 4 15 55 59 11 04-05 pm 28 21 10 12 9 9 8 30 55 72 12 05-06 pm 36 27 13 16 14 14 9 33 72 90 13 06-07 pm 40 30 12 14 9 9 12 44 73 98 14 07-08 pm 28 21 11 13 8 8 10 37 57 79 15 08-09pm 35 26 18 22 10 10 8 30 71 87 16 09-10pm 28 21 10 12 7 7 7 26 52 66 17 10-11pm 12 9 9 11 8 8 5 19 34 46 18 11-12pm 14 11 8 10 9 9 4 15 35 44 19 12-01am 11 8 7 8 8 8 3 11 29 36 20 01-02am 12 9 6 7 7 7 2 7 27 31 21 02-03am 10 8 5 6 8 8 3 11 26 33 22 03-04am 14 11 4 5 9 9 2 7 29 32 23 04-05am 15 11 3 4 6 6 3 11 27 32 24 05-06am 14 11 2 2 5 5 4 15 25 33



3.7 SOIL ENVIRONMENT

It is essential to determine the potential of soil in the area and identify the current

impacts of urbanization and industrialization on soil quality and also predict impacts,

which may arise due to the plant operations. Accordingly, a study of assessment of the

baseline soil quality has been carried out.

For studying soil profile of the region, sampling locations were selected to assess the

existing soil conditions in and around the project area representing various land use

conditions. The physical, chemical and heavy metal concentrations were determined.

The samples were collected by ramming a core-cutter into the soil up to a depth of 90

cm.

Six locations within 10-km radius of the proposed plant boundary were selected for soil

sampling. At each location, soil samples were collected from three different depths viz.

30 cm, 60 cm and 90 cm below the surface and are homogenized. This is in line with IS:

2720 and Methods of Soil Analysis, Part-1, 2nd edition, 1986 of (American Society for

Agronomy and Soil Science Society of America). The homogenized samples were

analyzed for physical and chemical characteristics. The soil samples were collected

during summer season. Sampling Locations are detailed in Table 3.18. and Figure

3.6.The analysis results are given in Table 3.19.

TABLE 3.18: SOIL SAMPLING LOCATIONS

S. No.

Code Name of Sampling Location

Distance (km) w.r.t Project


1. S1 Plant Site -- -- 2. S2 Gopavaram 1.43 NNE 3. S3 Ramapalem 3.84 NW 4. S4 Bhimolu 1.98 SW 5. S5 Surayyapeta 2.31 SE 6. S6 Tupakulagudem 5.88 E



FIGURE 3.6: SOIL SAMPLING LOCATIONS MAP



TABLE 3.19: SOIL SAMPLING ANALYSIS RESULTS

S.No Parameters S1 S2 S3 S4 S5 S6 1 pH(1:5 Ratio) -- 8.32 8.18 7.82 8.13 7.92 8.14

2 Electrical Conductivity (1:5 Ratio) mhos/cm 162.3 239 187.2 172.6 192.6 198.5

3 Bulk Density g/cc 1.15 1.14 1.18 1.32 1.12 1.21 4 Moisture Content % 6.8 4.6 3.2 3.4 5.68 3.7 5 Nitrates as N mg/Kg 56.8 62.8 60.2 54.6 72.56 53.68 6 Phosphorous as P mg/Kg 7.59 6.38 5.98 6.45 3.08 6.23 7 Potassium as K mg/Kg 68.8 58.4 56.8 75.4 68.4 71.5 8 Sodium as Na mg/Kg 72.5 79.5 62.4 62.8 56.2 57.3 9 Calcium as Ca mg/ kg 620 424.6 430 480 465.30 520

10 Magnesium as Mg mg/ kg 90.0 84.2 54.0 49.6 84.3 68.4 11 Total Organic Carbon % 0.75 0.72 0.69 0.68 0.38 0.39

12 Type of Soil -- Sandy Clay Loam

Sandy Loam

Sandy Loam

Sandy Loam

Sandy Loam

Sandy Loam

a) Sand (%) -- 48 49 42 42 42 45 b) Silt (%) -- 34 30 32 30 32 28 c) Clay (%) -- 18 24 20 19 14 16

13 Copper as Cu mg/ kg 8.72 11.8 16.45 6.89 12.32 7.56 14 Chromium as Cr mg/ kg 30.15 32.7 43.12 29.63 22.5 24.5 15 Cadmium as Cd mg/ kg < 0.5 <0.5 <0.5 <0.5 < 0.5 <0.5 16 Zinc as Zn mg/ kg 4.2 3.8 4.0 3.9 3.4 3.7 17 Lead as Pb mg/ kg < 5.0 < 5.0 < 5.0 < 5.0 < 5.0 < 5.0 18 Nickel as Ni mg/ kg 19.32 16.8 10.56 10.32 10.32 10.45 19 Sulphates as SO4 mg/ kg 42.4 42.6 48.6 47.9 44.78 38.6



The following are the highlights of soil quality in the study area:

pH of the soil samples were found to be in the range of 7.82 – 8.32

Soils in the area were found to be Sandy Loam, Sandy Clay Loam in texture.

Total Organic Carbon content of the soil samples were in the range of 0.38 -

0.75 %

3.8 LAND USE PATTERN

Land use, in general, reflects the human beings activities on land, whereas the word

land cover indicates the vegetation, agricultural and artificial manmade structures

covering the land surfaces. Identification and periodic surveillance of land uses and

vegetation covers, in the vicinity of any developmental activity is one of the most

important components for an environmental impact assessment, which would help

determine the impact of the project development activity on the land use pattern.

3.8.1 DATA USED

The data is used for the preparation of different maps to study the natural resources.

The data is used by using the application of Remote Sensing and GIS technologies.

TABLE 3.20 : SHOWING THE DETAILS OF SOURCES & THE MAPS PREPARED

S No. Source Maps Prepared 1 Survey of India’s topographic maps and

satellite imageries Drainage map

2 Satellite imageries Land use / Land cover

TABLE 3.21: SHOWING THE TOPOGRAPHIC MAPS

S No. Topographic Map No. Scale Year of Survey Year of

Publication 1 65 G/8 1: 50,000 2010 2011 2 65 G/11 1: 50,000 2010 2011 3 65 G/12 1: 50,000 2010 2011

Source:Survey of India’s Topographic Maps



TABLE 3.22:SATELLITE DATA OF NATIONAL REMOTE SENSING CENTRE

Sl. No. Season Sensor path/row Satellite/Sensor Date of Pass

1. Khariff 103-61-D IRS RS2 LISS IV 25 October 2015

3.8.2 LAND USE / LAND COVER MAP

Land use / land cover map is prepared by visual interpretation of high-resolution satellite

data with the help of Survey of India Topographic maps on 1:50,000 scale. Two

seasons’ data (Khariff year 2015) is used for the delineation of different units. The units

are confirmed by the ground truth/field visits.

Level-II classification of National (Natural) Resources Information System (NRIS) has

been followed for the delineation of units.

Land use/ Land cover map of the study area is integrated with village map and analyzed

with the help of GIS to get the village wise findings of the present land use of the study

area, which is given elaborately in the following tables:

Land use refers to man’s activities and various uses, which are carried on land. Land

cover refers to natural vegetation, water bodies, rock/soil, artificial cover and others

resulting due to land transformation. Although land use is generally inferred based on

the cover, yet both the terms land use and land cover are closely related and

interchangeable. Information on the rate and kind of change in the use of land

resources is essential to the proper planning, management and regulation of the use of

such resources.

Knowledge about the existing land use and trends of change is essential if the nation is

to tackle the problems associated with the haphazard and uncontrolled growth. A

systematic framework is needed for updating the land use and land cover maps that will

be timely, relatively inexpensive and appropriate for different needs at national and state

level. The rapidly developing technology of remote sensing offers an efficient and timely

approach to the mapping and collection of basic land use and land cover data over

large area. The satellite imageries are potentially more amenable to digital processing

because the remote sensor output can be obtained in digital format. Land use data are



needed in the analysis of environmental processes and problems that must be

understood if living conditions and standards are to be improved or maintained at

current levels.

3.8.2.1 Basic Concepts of Land Use

Clawson has given nine major ideas or concepts about land. These are:

Location or the relation of a specific parcel of land to the poles, the equator, and

the major oceans and landmasses. There is also relationship between various

tracts of land, as well as a political location.

Activity on the land, for what purpose this piece of land or tract is used.

Natural qualities of land, including its surface and subsurface characteristics and

its vegetative cover.

Improvements to and on the land. This is closely related to the activity.

Intensity of land use or amount of activity per unit area.

Land tenure, i.e. who owns the land, which uses it.

Land prices, land market activity and credit as applied to land.

Interrelations between activities on the land and other economic and social

activities.

Interrelations in the use between different tracts of land.

3.8.2.2 Methodology for land use / land cover mapping

Flowchart showing the methodology adopted for land use/land cover mapping is for analysis

and interpretation two types of data are needed:

1. Basic data 2. Ground data 3. Data Analysis

1. Basic data includes:

Satellite data of LISS IV FX

Toposheets

Local knowledge

Area map on any scale to transfer details

Reports and other literature of the study area

2. Ground data: Ground data is very much essential to verify and to increase the

accuracy of the interpreted classes and also to minimize the field work.



3. Data analysis: For analysis and interpretation of satellite data, the study can be

divided into three parts:

Preliminary work

Field work

Post field work

A. Preliminary work includes:

to see the limitation of satellite data

to lay down the criteria for land use classification to be adopted

to fix the size of mapping units, which depends upon the scale

interpretation of different land use/land cover classes

demarcation of doubtful areas

preparation of field land use/land cover map

B. Field work:

Type of ground data to be collected

Selection of sample area for final classification

Checking of doubtful areas

Change in land use/ land cover due to wrong identification, fresh

development, nomenclature.

General verification

C. Post field work:

Reinterpretation or analysis or correction of doubtful areas

Transfer of details on base map

Marginal information

Preparation of final land use/land cover map

A map showing Satelite Imagery Showing in Figure 3.7. A map depicting major land

use/ land cover classes comprising lands under agriculture, fallow land, open/degraded

vegetation; lands falling under water bodies, scrub and lands under inhabitations is

presented at Figure 3.8 and Flow chart for LU/LC mapping methodology is presented at

Flow Chart 3.1.



The land use classification within a distance of ten kilometers from the project location

and the areas falling under the respective classifications are presented in Table 3.23:

FLOW CHART 3.1 : LU/LC MAPPING METHODOLOGY

Data source

Interpretation and mapping of land use / land cover categories

Basic data

IRS–LISS4-FMX

Preparation of base map

Ground verification of doubtful areas and modification of thematic details

Area estimation of each land use/land cover class

Final land use/land cover map with symbols and

colours

Development of interpretation keys based on image characteristics

Validation and final interpretation key

Secondary data



FIGURE 3.7: SATELLITE IMAGE OF THE STUDY AREA



FIGURE 3.8: LAND USE / LAND COVER MAP OF THE STUDY AREA


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter - III Page 43

TABLE 3.23 : LAND USE / LAND COVER STATISTICS OF THE STUDY AREA

FIGURE 3.9: PIE DIAGRAM OF LAND USE THE IN STUDY AREA

Built- Up Land11% Water

bodies14%

Crop Land63%

Forest4%

Wastelands8%

Sl. No. LANDUSE AREA (Sq. km) %

1. BUILT- UP LAND

A. Settlements B. Industrial area

24.178 9.106

7.7 2.9

2. WATERBODIES

A. Tank / River /Major canal etc.

44.274

14.1

3. FOREST A. Scrub forest

13.502

4.3

4.

CROP LAND A. Single crop B. Double crop C. Plantation

143.498

29.516 24.178

45.7 9.4 7.7

5.

WASTELANDS A. Land with scrub B. Land without scrub C. Stone quarry D. Stony waste area

19.154 4.082 1.57

0.942

6.1 1.3 0.5 0.3

TOTAL 314 100



3.9 ECOLOGICAL ENVIRONMENT

Ecosystem is an integrated unit that contains both animals and plants whose survival is

dependent on biotic and abiotic structure. Based on the type of distribution of organisms

and its physical setting the study area can be classified in to cropland, terrestrial and

aquatic ecosystems. Natural flora and fauna are important features of the environment.

They are organized into natural communities, agriculture/ horticulture species and

plantations, which are sensitive to outside influences. Integrating ecological thinking into

the planning process is urgent need in the context of deterioration of natural

environments, which is unwanted but direct consequence of development. Biological

communities, being dependent on the condition and resources of its location may

change due to change in the environment. Hence change in the status of flora and

fauna are elementary requirement of Environment Impact Assessment Studies.

Ecological systems along with its abiotic and biotic components are important features

of an environment. Ecological studies carried out under any EIA therefore have to focus

on the vegetation and the faunal elements. Systematic ecological studies carried out aid

in proper decision making. It is important to carry out these studies in order to gauge the

losses or benefits due to proposed project. Ecosystems provide human society certain

services that are crucial for the existence for human species. Many of the anthropogenic

activities cause environmental stress resulting in the damage and irreparable changes

in the ecological setting of an area.The ecological study was undertaken with the

objective of the following:

To assess the nature and distribution of vegetation in and around the project

site;

To assess the distribution of animal life spectra.

To assess the biodiversity and to understand the resource potential.

The 7.0 Acres area identified for the proposed unit at Tupakulagudem Village, Tallapudi

Mandal of West Godavari District is referred to hereafter as the core area while its

surroundings extending up to 10 Km radius is referred to as the buffer zone. The study

area consists of dominantly soil system where the irrigation is supported by network of

river canals. Consistent with the variety of soils, climate and the past management the



study area bears a variety with different species and composition. Essentially all are

tropical vegetation identified into various ecological formations. Trees, shrubs and herbs

were recorded for measuring plant‟s importance. Qualitatively, flora can be assessed

by delineating the type, its habitat, unique vegetation features and interrelations with

other community members. A sizable number of animal species were found to be

recorded by the forest department of the area. Apart from barren lands, open grassland,

herbs, shrubs, bushes and aquatic impoundments are favourable habitats for the wild

animals. Besides obtaining a sufficiency of food, self-preservation for the animals

implies the ability to protect itself against other animals which live in its surroundings,

against fellows of its own or other species, against enemies which seek to

harm or destroy it. Quite apart from their general alertness and quickness of movement,

characters in which they are equaled only by birds, mammals possess a varied armory

of weapons of offence and defense. A list of plants found in the core area is given in

Table 3.24. TABLE 3.24: LIST OF TREES FOUND IN THE CORE & BUFFER AREA

S,No Family Species Habit

1 Mimosaceae Prosopis juliflora Tree

2 Casuarinaceae Casuarina equisetifolia Tree

3 Meliaceae Azadirachta indica Tree

4 Anacardiaceae Anacardium occidentale Tree

5 Arecaceae Borassus flabellifer Tree

6 Anacardiaceae Mangifera indica Tree

7 Caesalpiniaceae Tamarindus indica Tree

8 Fabaceae Pongamia pinnata Tree

9 Caricaceae Carica Papaya Tree

10 Sapotaceae Achras sapota Tree

11 Moraceae Ficus amplissima Tree

12 Verbenacee Tectona grandis Tree

13 Rubiaceae Morinda tinctoria Tree



TABLE 3.25: LIST OF SHRUBS & HERBS FOUND IN THE CORE & BUFFER AREA

S.No Family Species Habit

1. Euphorbiaceae Kirganelia reticulata Shrub

2. Euphorbiaceae Jatropha gossypifolia Shrub

3. Acanthaceae Acanthus ilicifloius Shrub

4. Asclepiadaceae Calotropis procera Shrub

5. Solanaceae Cestrum diurnum Shrub

6. Acanthaceae Adhatoda vasica Shrub

7. Solanaceae Datura innoxia Shrub

8. Acanthaceae Barleria buxifolia Shrub

9. Musaceae Musa sapientum Herb

10. Apocyanaceae Rauvolfia canescens Herb

11. Malvaceae Sida acuta Herb

12. Malvaceae Abutilon indicum Herb

13. Cactaceae Opuntia dillennii Herb

14. Asparagaceae Asparagus racemosa Climber

15. Convolvulaceae Ipomoea tuba Climber

16. Asclepiadaceae Sarcolobus carinatus Climber

17. Asteraceae Wedelia trilobata Climber

18. Vitaceae Vitis trifolia Climber

19. Lauraceae Cassytha filiformis Climber

3.9.1 Terrestrial fauna of the Core area and the Buffer zone:

As the animals, especially vertebrates and the winged invertebrates move from place to

place in search of food, shelter, mate or other biological needs, separate lists for core

and buffer areas are not feasible. Though there are two blocks of reserved forests in

the buffer zone, they are in the form of small isolated patches. As these forest blocks

are surrounded by villages on all sides, they are subject to biotic pressures of grazing

and harvesting. As such there are no chances of occurrence of any rare or endangered

or endemic or threatened (REET) species within the core or buffer area. There are no

Sanctuaries, National Parks, Tiger Reserve or Biosphere Reserve or Elephant Corridor



or other protected areas within 10 Km of radius from core area. It is evident from the

available records, reports and circumstantial evidence that the entire study area

including the core and buffer areas were free from any endangered animals. Among

the Mammals, only Squirrels, Mongoose, Rats, Bandicoots and Rabbits were seen

frequently during the survey. Monkeys were also rare. Among the reptiles, Lizards,

Garden lizards were very common. Rat snake and Monitor lizard were seen once

during the survey. Other reptiles were very rare. The amphibians were also rare. List of

vertebrates other than birds found in and around the project site area is given in Table

3.26. A list of birds is given in Table 3.28. There were no resident birds other than

Crows, Parrots, Doves, and Weaver birds, Swifts, Quails and Mynas. It is apparent

from the list that none of the species with the sole exception of Peacock either spotted

or reported is included in Schedule I of the Wildlife Protection Act. Peacocks are fairly

common in these areas. They do not come under the threatened category of the IUCN.

Further it is easy to multiply Peacocks and they can be easily domesticated if permitted.

TABLE 3.26 : LIST OF VERTEBRATES OTHER THAN BIRDS OBSERVED IN THE STUDY AREA.

S.No Family Scientific Name Common Name WPA MAMMALS

1. Canidae Canis aureus Jackal II 2. Canidae Vulpes bengalensis Indian Fox II 3. Felidae Felis chaus ungle Cat II 4. Viverridae Viverricula indica Small Indian Civet II 5. Herpestidae Herpestes edwardsii Grey Mongoose II 6. Muridae Bandicota indica Bandicoot rat V 7. Muridae Rattus rattus House Rat V 8. Muridae Mus musculus House Mouse V 9. Muridae Mus booduga Little Indian Field

Mouse V

10. Pteropodidae Pteropus giganteus Indian Flying Fox V 11. Pteropodidae Rosettus leschenaultia Fulvous fruitbat V 12. Pteropodidae Cynopterus sphinx Short nosed fruitbat V

REPTILES 13. Agamidae Calotes versicolor Common calotes - 14. Agamidae Sitana ponticeriana Fanthroated

Lizard -

15. Agamidae Psammophilous blanfordianus

Rock Agama -



S.No Family Scientific Name Common Name WPA 16. Scincidae Eutropis arinata Common skink - 17. Varanidae Varanus bengalensis Monitor lizard II 18. Colubridae Ptyas mucosus Rat snake II 19. Elapidae Naja naja Spectacled cobra II AMPHIBIANS 20. Bufonidae Duttaphrynus

melanostictus Common Asian Toad -

21. Dicroglossidae Hoplobatrachus tigerinus

Indian Bull frog -

22. Dicroglossidae Euphlyctis cyanophlyctis

Indian Skipper Frog -

WPA indicates Schedule number in the Indian Wildlife (Protection) Act.

TABLE 3.27 : LIST OF BIRDS EITHER SPOTTED OR REPORTED FROM THE AREAS IN AND AROUND THE PROJECT SITE

S.No Scientific Name Common Name Family WPA 1. Meropidae Merops orientalis Small green bee eater IV 2. Dicaeidae Dicaeum agile Thick-billed

flowerpecker IV

3. Monarchinae Terpsiphone paradisi Asian Paradise flycatcher IV

4. Sturnidae Acridotheres tristis Common mynah IV 5. Coraciidae Coracias benghalensis Indian roller IV 6. Scolopacidae Tringa ochropus Green sandpiper IV 7. Phalacrocoracidae Phalacrocorax

fuscicollis Indian shag IV

8. Anatidae Nettapus coromandelianus

Cotton teal IV

9. Phasianidae Perdicula asiatica Jungle bush quail IV 10. Corvidae Corvus splendens House crow IV 11. Apodidae Zoonavena sylvatica Indian white rumped

spinetail V

12. Laridae Larus brunnicephalus Brown headed gull IV WPA indicates Schedule number in the Indian Wildlife (Protection) Act.

3.9.2 Aquatic flora and fauna:

There are many perennial water bodies and Godavari River in the study area. Most of

the study area has dense cultivation of paddy together with groves of coconut palms.



3.10. SOCIO-ECONOMIC ENVIRONMENT

The socio- economic aspects of people in the 10 km radius of the plant site at

Tupakulagudem, Tallapudi, West Godavari District, Andhra Pradesh was analyzed. The

socio-economic data forms the basis for developing a suitable enterprise social

responsibility plan to address the needs of the population.

3.10.1 Methodology Adopted for the Study

The methodology adopted for the study mainly includes review of published secondary

data (Primary Census Abstract of Census-2011) with respect to population, density,

household size, sex ratio, literacy rate and occupational structure for 10 km radius study

area.

3.10.2. Distribution of Population in the study area

As per 2011 census the study area consists of 2,17,634 persons inhabited in the study

area of 10km radial distance from the periphery of the project. The distribution of

population in the study area is given in Table 3.29.



TABLE 3.28: THE DEMOGRAPHIC DETAILS S.No Village Name Total

population Male

Population Female

Population 0-6 Y Male Population

0-6 Y Female Population

0-6 Y Total Population

1 Pragadavaram 10755 5396 5359 517 505 1022 2 Lakshminarayana Devipeta 4393 2226 2167 257 254 511 3 Gutala 7955 3958 3997 407 378 785 4 Tallapudi 52785 26295 26490 2852 2760 5612 5 Ragolapalle 802 396 406 44 33 77 6 Thupakulagudem 1078 546 532 62 64 126 7 Pochavaram 955 463 492 24 36 60 8 Prakkilanka 2820 1385 1435 163 158 321 9 Gajjaram 3510 1759 1751 193 187 380

10 Annadevarapeta 8671 4325 4346 495 455 950 11 Kukunuru 2829 1390 1439 144 136 280 12 Vegeswarapuram 5601 2794 2807 318 331 649 13 Tirugudumetta 3822 1865 1957 202 208 410 14 Gopalapuram 62597 31040 31557 3199 3265 6464 15 Karagapadu 1921 963 958 112 105 217 16 Sagipadu 1601 813 788 99 90 189 17 Dondapudi 3408 1715 1693 201 179 380 18 Saggonda 111 58 53 7 5 12 19 Bhimolu 3367 1675 1692 179 206 385 20 Kovvurupadu 2997 1514 1483 156 136 292 21 Guddigudem 3324 1667 1657 167 181 348 22 Nandigudem 2637 1328 1309 117 117 234 23 Gopalapuram 11573 5469 6104 526 558 1084 24 Vellachintalagudem 4952 2494 2458 257 269 526 25 Chityala 4669 2304 2365 248 255 503 26 Venkatayapalem 1555 779 776 101 92 193 27 Cherukumilli 1176 581 595 59 66 125 28 Kommugudem 79 38 41 0 2 2 29 Gopavaram 2632 1319 1313 135 133 268 30 Ramannapalem 3059 1562 1497 135 138 273 Total 217634 108117 109517 11376 11302 22678

The male and female population constitutes about 49.68 % and 50.32 % in the study area respectively.



FIGURE 3.10: Diagram Showing Total Population Distribution in the Study Area

3.10.3. Literacy & Illiteracy Rate Literacy level is quantifiable indicator to assess the development status of any area. The

literate male and female in the study area are 57,536 and 53,856 which implies that the

percentage of literacy rate is 53.22% with male and 49.18% with female respectively.

The male and female illiterates including 0-6 year’s population in the study area are

50,581 and 55,661 respectively which implies that the percentage of illiteracy rate is

46.78% with male and 50.82% with female respectively. The distribution of literate and

literacy rate in the study area is given in Table3.29. The graphical presentation of

literates and illiterates in study area is given in figure 3.11. TABLE 3.29: Distribution of Literacy Rate and Illiteracy Rate in the Study Area

S.No. Particulars Population

1 Male Population 108117

2 Female Population 109517

3 Total Population 217634

4 Male population Literates 57536

5 Male population illiterates 50581

6 Male population Literates % 53.22

7 Male population Illiterates % 46.78

8 Female population Literates 53856

9 Female population Illiterates 55661



S.No. Particulars Population

10 Female population Literates % 49.18

11 Female population Illiterates % 50.82

FIGURE 3.11: The Diagram Showing Literates and Illiterates in Study Area

3.10.4. Occupational Structure

The occupational structure of residents of work participation rate in the study area is

studied with reference to main workers, marginal workers and non workers. The main

workers include 10 categories of workers defined by the Census Department consisting

of cultivators, agricultural laborers, those engaged in live-stock, forestry, fishing, mining

and quarrying; manufacturing, processing and repairs in household industry; and other

than household industry, construction, trade and commerce, transport and

communication and other services.

The marginal workers are those workers engaged in some work for a period of less than

six months during the reference year prior to the census survey. The non-workers

include those engaged in unpaid household duties, students, retired persons,

dependents, beggars, vagrants etc.; institutional inmates or all other non-workers who

do not fall under the above categories.

Occupational pattern of the concerned study area is recorded to assess skills of people.

57536 53856

3920544359

Male Female

Literates Illiterates



Occupational pattern also helps in identifying dominating economic activity in the area.

In the study area the main and marginal workers are 97,882 (44.98%) and 8603

(3.95%) respectively of the total population while the remaining 1,11,149 (51.07%)

constitutes non-workers.

TABLE 3.30: Occupational Structure in Study Area

S.No. Parameter Total Male Female 1 Main Workers 97882 64324 33558 2 Marginal Workers 8603 3286 5317 3 Non-Workers 111149 40507 70642

Total Population 217634 108117 109517

FIGURE 3.12: The Diagram Showing Occupational Structure in Study Area

3.10.5 CIVIC AMENITIES AVAILABLE IN THE STUDY AREA

The proposed project is coming up, at ‘Tupakulagudem’ Village, Tallapudi Mandal, West

Godavari District, Andhra Pradesh – where the basic social amenities like Education,

Emergency Medicare, Drinking-Water, Communications, Roads and Power supply are

readily available.



As for Educational facilities, they are available either within the Village or Major Village

& Semi-Urban Centre, Kovvuru Town, to almost all the populations of the Study Area.

A) Power and Energy:

All Villages, in the Project Study Area, are electrified – both for common facilities like,

Street Lights, Public Water Pumping, etc. and also almost all houses are electrified for

home lighting, while LPG, Kerosene Oil and in some cases Waste Agri-Waste, Fallen

Firewood, Cow Dung Cakes, etc. are used for cooking purpose.

B) Health and Medical Facilities:

Most Villages have Visiting ANMs / Health Counseling-cum-Primary Health Care Mobile

Units or PHCs (Primary Health Centers). For Maternity and Specialist Care & basic

Diagnostics, adequate facilities are available at ‘Rajahmundry City’, which is at a

distance of 24 KMs., ‘Eluru’, which is the District Head Quarters is at a distance of 69

KMs. from the proposed project site. And for Critical and Advanced Medicare &

Diagnostics, local communities visit Rajahmundry & Eluru.

Also Ambulance is available on 108 for emergencies to evacuate patients of serious

health condition/s to the Multi-Specialty Hospitals – both Government & Private –

located in Eluru and Rajahmundry.

C) Tele-Communications:

Telecommunication facility in the Project Study Area is adequate; BSNL Electronic

Telephone Exchange is available and BSNL Mobile / BSNL / Aircel / Airtel / Vodafone,

Idea Cellular Telecom. Services, Reliance, Docomo are very effective and are available

to almost everyone, in the Project Study Area.

D) Local Administration & Law:

While all the Villages and Hamlets, attached to any Village do have ‘Village Panchayats’

duly elected by the local electorates to assure Sanitation, Local Law & Order and to

coordinate with various Government Departments & Other Agencies, concerned for

local Sanitation, General Hygiene, Immunisation, Nutrition Programmes, Enhancement



of Literacy Levels and Crime / Law & Order as well as all Central and State

Governmental Developmental Projects.

E) Other Administrative Issues:

They are further supported by the Office of the Mandal Revenue Officer & Special

Officer / Revenue Divisional Officer (R.D.O.) sit at Tallapudi (8.10 KMs.) which is also

the Mandal Head Quarters and Eluru (69 KMs.), the Head Quarters of the District, of the

same name.

F) Transportation & Other Important Facilities:

The nearest Police Station, the Fire Station and Bus Station are located at Tallapudi

and there are also Bus-Stations or Bus-Stops at almost all Villages & Hamlets to all

major Towns & Cities.

3.10.6 Corporate Social Responsibility of the Project Proponent

Apart from the mandatory ‘Corporate Social Responsibility (CSR) Budgets, the

project proponent is advised to provide employment to the Qualified, Semi-

Literate, Un-Skilled, Women & Physically Handicapped from the Local Area as a

compensation for operating in cluster of Villages / Hamlets. Similarly, the

Qualified Local Area people should be preferred over others.

It is also advised that Project Proponent acts ethically & transparently in all its

dealings pertaining to the operations and pollution discharges of the Plant for the

local communities to become confident of the otherwise skeptical about Chemical

& Drug Manufacturing activities in the area due to the possible pollution of the

Air, Water & Soil.

ANTICIPATED ENVIRONMENTAL IMPACTS

& MITIGATION MEASURES

CHAPTER -IV


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter - IV Page 1

CHAPTER - IV

IDENTIFICATION AND PREDICTION OF ENIVORNMENTAL IMPACTS 4.1 INTRODUCTION

The major element involved in the process of Environmental Impact Assessment is the

Identification of impacts as it forms the basis for quantification and evaluation of

impacts. In this section, the impacts on the environment, either beneficial or deleterious

due to the proposed project have been identified. The aspects of the environment,

which are likely to be disturbed or damaged due to the proposed project, are

represented as parameters.

Prediction of impacts is the most important component in the Environmental Impact

Assessment studies for quantification and evaluation of impacts. Several scientific

techniques and methodologies are available to predict impacts of developmental

activities on physical, ecological and socio-economic environments. Such predictions

are superimposed over the baseline (pre-project) status of environmental quality to

derive the ultimate (post-project) scenario of environmental conditions. The prediction of

impacts helps in minimizing the impacts on environmental quality during the post project

execution.

The identified impacts for various components of environment viz., air, noise, water,

land, socio-economy, etc. are presented herewith. EIA is an activity or an attempt to

identify, predict, evaluate and communicate the likely environmental impacts of the

activity/project on the environment.

4.2 PREDICTION OF IMPACTS DURING CONSTRUCTION PHASE This includes the following activities related to construction of related structures and

installation of related equipment.



4.2.1 Impact on Land Use The land identified for the proposed Bulk Drug & intermediates manufacturing unit is

about 7.00 acre. Construction of plant will lead to permanent change in land use pattern

at the site. New industry establishment will attract additional settlements in surrounding

area due to new employment scope. It may alter the surrounding land use.

4.2.2 Impact on Land / Soil Environment

Physico-chemical changes in soil quality may occur due to spillage of various chemicals

on land around storage area. The impact will remain confided within the factory

premises it will change the quality of soil and impact will be of irreversible in nature. The

construction activities will result in loss topsoil and earthen material to some extent in

the plant area. However, it is proposed to use the soil and earthen material for

greenbelt development and leveling of project site. Greenbelt will be developed in

phased manner from construction stage onwards.

Construction impacts are only within plant site; no adverse impacts on soil in the

surrounding area are anticipated.

4.2.3 Impact on Topography

It is a new project, impact on topography is anticipated. Project activities include

excavation of soil at plant site and construction of buildings. During construction,

excavated soil will be restored to its original shape. Thus the impact during the

construction is reversible and short term and insignificant. During the operation phase of

the project, no impact is envisaged on the topography

4.2.4 Impact on Air Quality There will be impact on Air Environment during construction phase and also during

operation phase. The impact during construction phase will be short term and

reversible. However impacts during operation phase will have long term impacts due to

flue gas emission as well as process gas emission. But suitable air pollution control

measures will be adopted to keep the quality of air emission below the prescribed

norms so as to have minimal impact on air quality.



The main sources of emission during the construction period are the movement of

equipment at site and dust emitted during the leveling, grading, earthwork, foundation

works and exhaust emissions from vehicles and equipment deployed during the

construction phase is also likely to result in marginal increase in the levels of SO2, NOx,

SPM and CO.

4.2.5 Impact on Water Quality The water required for construction will be available near to the site. Sanitation facilities

(septic tanks and soak pits) are available for disposal of sanitary sewage generated by

the workforce. The overall impact on water environment during construction phase due

to proposed project is likely to be short term and insignificant.

4.2.6 Impact on Noise Levels Noise will be generated due to construction traffic for loading and unloading, fabrication

and handling of equipment and materials are likely to cause an increase in the ambient

noise levels. The areas affected are those close to the site. However, the noise will be

temporary and will be restricted mostly to daytime.

4.2.7 Impact on Ecology The proposed area is a non-forest land sparsely covered by perennial grasses, forbs

along with a few shrubs

The present project will not involve removal of any vegetation from the soil and

loosening of the topsoil generally causes soil erosion as it is. However, such impacts

will be confined to the project site and will be minimized through paving and water

sprinkling.

However, greenbelt will be developed within the plant site. The existing trees will be

preserved to the extent possible.

Thus, there will no major adverse impacts are envisaged on ecological environment due

to project activities



4.2.8 Impact on Socio-Economic Environment

Due to the proposed project there is no major negative impact on socio

economic environment, project will not cause any disturbance to any Habitat.

The proposed Project will create jobs for at least 50 persons. Thus industrial activity

will boost up the commercial and economical status of the locality to some

extent. And, the overall impacts on socio-economic environment due to the

proposed project are positive in nature and accrue to the community on the long-terms

basis.

4.3 MITIGATION MEASURES DURING CONSTRUCTION PHASE During construction phase, the construction activities like site leveling, grading,

transportation of the construction material cause various impacts on the surroundings.

However, the constructional phase impacts are temporary and localized phenomena

except the permanent change in local landscape and land use pattern of the project

site.

4.3.1 Land/Soil Environment Management The earthen material generated during excavations and site grading periods, shall be

properly dumped and slope stabilization shall be taken. The topsoil generated during

construction shall be preserved and reused for plantations.

Solid / hazardous waste generated will be stored separately in Hazardous Waste

storage area within the factory premises and disposed as per guidelines. The

hazardous waste storage area has non-percolating RCC floor and covered roof. Hence,

no significant negative impact is envisaged on the surrounding soil quality due to

presence of solid / hazardous waste within the plant premises.

More than 33 % of land will be developed as greenbelt.

4.3.2 Air Quality Management The activities like site development, construction and vehicular traffic contribute to

increase in SPM and NOx concentrations. The mitigation measures recommended to

minimize the impacts are:

Water sprinkling in construction area.



Proper maintenance of vehicles and construction equipment.

Tree plantation in the area earmarked for greenbelt development.

4.3.3 Water Quality Management The domestic sewage generated during the construction activity will be routed to septic

tanks followed by soak pit.

4.3.4 Noise Level Management Construction equipment and vehicular traffic contribute to the increased noise level.

Recommended mitigation measures are:

Good maintenance of vehicles and construction equipment.

Restriction of construction activities to day time only.

Plantation of trees around the plant boundary to attenuate the noise.

4.3.5 Ecological Management During construction, small shrubs in the plant premises are required to be cleared. The

measures required to be undertaken to minimize the impact on the ecology are:

The felling of trees will be kept at minimum.

The greenbelt will be developed.

4.3.6 Social community Management Constructional activities will generate employment to about 50 workers.

4.4 PREDICTION OF IMPACTS DURING OPERATIONAL PHASE This phase of the project is important because it generates long-term impacts as the

production starts.

The following activities related to the operational phase will have varying impacts on the

environment and are considered for impact assessment:

Air environment

Water resources and quality

Noise levels

Land use

Soil quality



Solid waste

Terrestrial and aquatic ecology

Demography and socio-economics.

Hydro Geology

4.5 AIR ENVIRONMENT

The impacts on air quality from project depend on various factors like design capacity,

configuration, process technology, raw material, fuel to be used, air pollution control

measures, operation and maintenance. Apart from the above, other activities associated

with transportation of fuel, raw materials and finished products, storage facilities and

material handling within the plant premises may also contribute to air pollution.

4.5.1 Source of Air Pollution The operational phase activities are expected to have long - term impacts on the air

quality. The main sources from proposed project are detailed below.

A. Flue gas Emissions Boiler and DG set are the two main sources of emissions from the plant. Vensar Laboratories Pvt. Ltd. proposed to install a 6 TPH coal fired/Agro waste boiler for plant

operations and the industry proposes to install a DG Set of 250 KVA capacity for

standby power during power failures only. The PM, SO2 and NOx are the main air

pollutants generated from the boilers and DG sets.

The emissions from the boiler stacks and DG Set Stacks are given in Table 4.1 & 4.2.

TABLE 4.1: EMISSION DETAILS FROM BOILER STACK



Type of Fuel -- Indian Coal/Agro waste Coal Consumption TPD 15.0 Ash Content % 47 Sulphur Content % 0.8 Nitrogen Content % 1.07 No. of Stacks No 1 Height of stack m 32





Diameter of Stack m 0.60 Temperature of Flue Gas oC 110 Velocity of Flue Gas m/s 8.50 Particulate Matter at outlet of Bag filter (Based on 115 mg/Nm3 at outlet)

gm/sec 0.62

Sulphur dioxide emission gm/sec 1.39 Oxides of Nitrogen emission

gm/sec 1.86

Pollution control equipment

- Cyclone separator followed by suitable pack

of Bag filters

TABLE 4.2: EMISSION DETAILS FROM DG SET STACK

Capacity In KVA

Emission of SPM in mg/Nm3



Stack dia. In m

Flue Gas

Temp. in OC

Stack Height in m

Flue gas Velocity In m/sec.

250 KVA (Proposed)

58.0 24.0 30.0 0.30 250 10 18.24

B. Process Emissions The most probable emitted pollutants from process are HCl, HBr, CO2, H2 and O2. The

emission from the process is mainly liberated gases from various reactions. The various

gases emanating from reactions shall be scrubbed in a 2 stage scrubber to control the

gaseous emission into the atmosphere, by using the suitable scrubbing media. Apart

from this all the reactors are connected with primary and secondary condensers to

mitigate the solvent evaporation losses from process.

C. Fugitive emission

The main sources of fugitive emissions from project are handling of raw materials and

Solvents. The solvents will be stored in drums in elevated flat from under the roof. Bulk

quantities will be stored in storage tanks with vent condensers to avoid the fugitive

emissions. Solvents are handled in closed conditions thereby reducing the losses in the

form of evaporation.



4.5.2 Prediction of Impacts on Air Environment

The objective of dispersion modeling is to predict the ground level concentration during

the operation of proposed plant and its impact on ambient air quality of the area. The

impact on air quality due to emissions from single source or group of sources is

evaluated by use of mathematical models. When air pollutants are emitted into the

atmosphere, they are immediately diffused into surrounding atmosphere, transported

and diluted due to winds. The air quality models are designed to simulate these

processes mathematically and to relate emissions of primary pollutants to the resulting

downwind air quality. The inputs include emissions, meteorology and surrounding

topographic details to predict the impacts of conservative pollutants. The impacts of air

pollutants were predicted using Gaussian air dispersion model, which is selected on the

basis of existence of multiple point sources within the industrial complex and the plain

terrain at the project site. The Gaussian air dispersion model has been developed to

simulate the effect of emissions from point sources on air quality. Gaussian model is

extensively used for predicting the Ground Level Concentrations (GLCs) of conservative

pollutants from point, area and volume sources. The impacts of primary air pollutants

are predicted using this air quality model keeping in view the plain terrain at the project

site.

The micrometeorological data monitored at project site during study period have been

used in this model.

The Gaussian model provides estimates of pollutant concentrations at various receptor

locations. It is, an hour-by-hour steady state. Gaussian model which takes into account

the following:

Terrain adjustments

Stack-tip downwash

Gradual plume rise

Buoyancy-induced dispersion, and

Complex terrain treatment and consideration of partial reflection

Plume reflection off elevated terrain

Building down wash



Partial penetration of elevated inversions is accounted for hourly source emission rates,

exit velocity and stack gas temperature. Gaussian air dispersion models were used to

estimate the ambient air quality levels at different monitoring stations due to stack

emissions. Only two stability conditions based on the meteorology aspects were used to

calculate the theoretical maximum ground level concentration. Comparing the actual

data and data generated from mathematical modeling, it highlights that the stability

condition E & A-B were predominant in the region. Using the estimated stack emission

data and wind speed directions, a mathematical model was prepared to establish the

ground level concentration in the region.

Methodology

Prediction of GLC values are made by using Industrial Source Complex Short Term

Model Version–3 (ISCST-3) software approved by U.S. Environmental Protection

Agency (USEPA). This model uses a steady state, sector-averaged Gaussian plume

equation for application in complex terrain (i.e. terrain stack or release height) and is run

using stability classes developed by Pasqual and Gifford.

Following are the assumptions made while using the model:

No dry and wet depletion of pollutants

Receptors are on flat terrain with no flag pole

Data Used for Computation

Stack emissions data have been used for prediction of short-term incremental GLC

values of PM, SO2 & NOx using the meteorological data collected at site during one

month i.e March 2016. Details of the data used for computations are given below:

Source Characteristics/Release Characteristics

The details of estimated stack emissions load are given in Table 4.1.

Meteorological Data

The meteorological data recorded continuously during one month i.e March 2016, on

hourly basis. Wind speed, wind direction and temperature have been processed to



extract the 24 hourly mean meteorological data as per the guidelines of IMD and MoEF

for application in ISCST3 Model. Mixing heights of the project area have been taken

from CPCB publication named “Hourly Mixing Height and Assimilative Capacity of

Atmosphere in India”.

Dispersion Modeling Results

The 24 hourly average ground level concentration (GLC) values from proposed plant

have been computed for PM, SO2 & NOx considering topographical features around the

proposed plant and applicable stability classes. The maximum 24 hourly average GLC

values for PM, SO2 & NOx from proposed plant are given in Table 4.3 to Table 4.4.

Corresponding isopleths plotted are shown in Figure 4.1 to Figure 4.3 for SPM, SO2 &

NOx.

TABLE 4.3: PREDICTED 24-HOURLY SHORT TERM INCREMENTAL CONCENTRATIONS

Period Maximum Incremental GLCs (μg/m3) Distance

(km)

Direction SPM SO2 NOx

March 2016 0.76 1.70 2.28 1.0 NNE

TABLE-4.4 RESULTANT CONCENTRATIONS DUE TO INCREMENTAL GLC's

Pollutant Maximum Baseline Concentration

(μg/m3)

Incremental Concentrations due to

Proposed Project (μg/m3)

Resultant Concentration

(μg/m3) PM 68.32 0.76 69.08

SO2 14.05 1.70 15.75

NOx 23.11 2.28 25.39

With this marginal contribution due to the proposal of the project, the levels of SPM,

SO2 &NOx, will remain below the 24 –hourly ambient air quality standards for SO2 &

NOx (80 μg/m3) and PM10 (100μg/m3) prescribed by CPCB. The operation of proposed

plant is not likely to cause any significant impact on the ambient air quality of the study

area.



FIGURE - 4.1: SHORT TERM 24 HOURLY INCREMENTAL GLCs OF SPM

NORTH

SOUTH

WEST EAST4%

8%12%

16%20%

0.01

0.08

0.15

0.22

0.29

0.36

0.43

0.5

0.57

0.64

Concentration μg/m3 -10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000

-10000

-8000

-6000

-4000

-2000

0

2000

4000

6000

8000

10000



FIGURE - 4.2: SHORT TERM 24 HOURLY INCREMENTAL GLCs OF SO2

NORTH

SOUTH

WEST EAST4%

8%12%

16%20%

-10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000-10000

-8000

-6000

-4000

-2000

0

2000

4000

6000

8000

10000

0.01

0.21

0.41

0.61

0.81

1.01

1.21

1.41

Concentration µg/m3



FIGURE - 4.3: SHORT TERM 24 HOURLY INCREMENTAL GLCs OF NOX

NORTH

SOUTH

WEST EAST4%

8%12%

16%20%

-10000 -8000 -6000 -4000 -2000 0 2000 4000 6000 8000 10000-10000

-8000

-6000

-4000

-2000

0

2000

4000

6000

8000

10000

0.01

0.21

0.41

0.61

0.81

1.01

1.21

1.41

1.61

1.81

Concentration μg/m3



4.6 WATER ENVIRONMENT

The total water requirement for the proposed unit is 79.71 KL/day. The detailed breakup

of the water requirement is shown in Table 4.5 and required water will be met from

ground water. The total waste water generated will be 40.00 KLD which is from process,

floor & reactor washes, cooling tower bleed, boiler blow down, scrubber, DM plant and

plant domestic wastewater shown in Table 4.5.

TABLE 4.5: TOTAL WATER REQUIREMENT

S.No Purpose Water consumption In KLD


Total 79.71

Out of Total Water consumption of 79.71 KLD an amount of 21.24 KLD of water will be

recovered by the ZLD system and reused, Hence, Total fresh water requirement is

58.47 KLD and will be met from Ground Water.

TABLE 4.6: TOTAL WASTE WATER GENERATION

Unit HTDS

KLD

LTDS

KLD

Effluent Generation in KLD

Treatment Method

Process 21.00 7.60 28.60 HTDS effluent sent to ETP with MEE System

LTDS effluents treated in ETP – RO Plant / RO Rejects to MEE System and RO permeate to reuse, Condensate from MEE to reuse and MEE residue to ATFD.






4.7 NOISE ENVIRONMENT

The main sources of noise pollution in the plant are Boiler, Reactors, DG Sets, Air

compressors, compressors and other Noise generating units. Vehicular movements

during operation phase for loading / unloading of raw materials and finished products

and transporting activity may also increase noise level.

Noise levels in the ambient air are well within the permissible limits given by the

National Ambient Noise level standards as confirmed during baseline study. Leq values

of the noise levels within the plant premises will be kept less than 75 – 70 db [A] [during

day time and night time] which will be within the permissible limit.

4.8 IMPACT ON LAND USE

The current land use type of project site is sheet rock area. This land will be

converted in to industrial area.

According to project site 7.00 Acres (28328.00SQM) area will change into

industrial land.

As per land break up single crop land and Double crop lands are the major land

use type covering the study area. Crop lands are influencing factors to the

environment.

As per totally new industry will established, relatively settlements also will

increase in surrounding area due to new employment. It may alter the surrounding

land use.

4.9 SOIL CONSERVATION One of the adverse impacts of a project may be enhanced soil erosion. Any plan or

activity or action that is capable of preventing soil erosion is capable of conserving soil.

Soil erosion is mainly on account of rain and flood. Soil erosion is due to heavy rains

and floods coupled with improper and unplanned land use. The damage due to rains

and floods can be minimized with appropriate prevention and mitigation measures.

The second asp Plan for conservation of soil is site - specific. Action plan for soil

conservation should take in to account the following criteria and considerations:



i) Soil: Extent or area of vacant land; topography of soil; slope or gradient;

texture, structure and composition of soil; land use and land cover;

connectivity with the adjacent land mass

ii) Rainfall: Intensity and frequency of rainfall and drainage.

Based on the above, engineering or biological or integrated land, water and

afforestation programme are designed. Measures for prevention of surface runoff and

water conservation are capable of preventing soil erosion.

4.10 IMPACT OF SOLID WASTE The details of hazardous waste to be generated from the proposed project, is

mentioned at Chapter -2. The current practice of storage of generated hazardous waste,

in a closed room having an impervious bottom, and disposed of as per the prescribed

guidelines will be continued for the additional generation of hazardous waste. Hence,

the impact due to the same will be negligible as the handling of hazardous waste to be

generated will be disposed as per guidelines. The details of solid waste will be shown in

below Table 4.7.

TABLE 4.7: HAZARDOUS / SOLIDWASTE GENERATION AND DISPOSAL MODE


Quantity In










Solid Waste Details




4.11 IMPACTS ON ECOLOGY

Prediction of impacts is based both on the direct and indirect; short-term as well as

long-term; irreversible and irreversible impacts that are most likely to occur owing to

the proposed industrial activity during establishment and operation. The ecological

factors that are considered most significant as far as the impact on flora and fauna are

concerned:

1. Whether there shall be any reduction in species diversity

2. Whether there shall be any habitat loss or fragmentation

3. Whether there shall be any additional risk or threat to the rare or endangered or

endemic or threatened (REET)species

4. Whether there shall be any impairment of ecological functions such as (i)

disruption of food chains, (ii) decline in species population and or (iii) alterations in

predator-prey relationships.

As there are no REET species in the core area, no species is going to be lost on

account of the proposed industry. Most of the plants listed in core are going to be

destroyed on account of the establishment of the industry. As there are no REET

species, the proposed project is not going to pose any threat to local flora and fauna.

No direct or indirect damage is expected to the flora and fauna of the buffer zone.

Further, as there are no rare or endangered or endemic or threatened (REET) species,

the project does not pose any threat to the flora and fauna of the study area. As the

industry is required to operate and maintain the emissions and effluents within the limits

specified by the CPCB / APPCB, the effects of the industry on the flora and fauna of the

buffer zone may be negligible. Neither the storm water nor the effluent water nor any

other kind of rain or waste water from the industry shall get in to the drinking water

resources. Further tall, wind resistant and evergreen trees will be grown in the green

belt to act a wind break. Hence, the anticipated environmental impacts on the flora and

fauna of the study area are negligible and easily reversible. It is not going to create any

kind of environmental stress to the local flora and fauna.



4.12 IMPACTS ON SOCIO- ECONOMY

During the erection phase short term direct or indirect employment will be

generated.

This Project will generate and an additional direct employment for at least 50 persons

including, skilled, semi-skilled & unskilled labour and office staff. The indirect

employment will also will go up in local transportation, shopkeepers’ business and other

casual employment for many people.

The Project Proponent shall arrange to give First preference to the Local people

wherever found suitable for all the jobs in the plant. Economic status of the local people

will improve due to the increased employment & business opportunities, thereby,

making a positive impact to the Local Economy. Educational, medical and housing

facilities in the study area will considerably improve. Thus, the proposed project

will have significant positive impact on the socio-economic environment.

4.13 IMPACTS ON HYDROLOGY AND GEOLOGY

As there are exposures / outcrops in the close vicinity of the proposed industry the

impact on Geology will have negligible impact.

4.14 MITIGATION MEASURES DURING OPERATIONAL PHASE 4.14.1 Mitigation Measures for Air Environment

The industry will take measures for reduction of fugitive emissions by providing

vent condensers to the Tanks.

Chilled brine circulation will be used to condensate the solvent vapor in receivers

which ensures the recovery around 95% and also controlled by closed operations

and handling methods. Good ventilation will be provided to reduce the workroom

concentrations.

Fugitive emissions will be reduced by providing vent condensers to the storage

tanks and all the reactors are provide with primary and secondary condensers

with chilled brine circulation to avoid fugitive emission and solvent losses which

ensures the recovery around 95% and also controlled by closed operations and

handling methods.



The reactor generating solvent vapors will be connected to condensers with

receivers. The height of the solvent receiver tank vent is above production block

roof level and the diameter is 20 mm. The maximum solvent loss is around 5 %.

Adequate stack height of 32 Mtrs will be provide to the 6 TPH boiler and stack

monitoring facilities for the periodic monitoring of the stack to verify the

compliance of the stipulated norms. Apart from this Cyclone Separators’ followed

by Bag filters will be provided to the boiler.

In order to minimize the air pollution, unit will develop green belt on and around

its premises.

Process emissions will be sent to scrubbing system and will be mitigated by

using suitable scrubbing media.

Solvents are handled in closed conditions thereby reducing the losses in the form

of evaporation.

Providing vent condensers to the tanks and chilled water circulation will be used

to condensate the solvent vapor in receivers which ensures the maximum

recovery and also controlled by closed operations and handling methods.

4.14.2 Mitigation Measures for Water Environment

Unit proposed to recharge ground water during the monsoon to balance the

water table to make a recharge sump in own premises.

Minimization of water use

Zero Liquid Discharge System

Use of high-pressure hoses for cleaning the floor to reduce the amount of

wastewater generated.

4.14.3 Measures for hazardous/solid waste To reduce the quantity of solid / hazardous waste generation as well as possible

contamination of land (soil) due to spillages / leaks from the plant operations, following

Mitigation measures can be implemented:

There will not be any leakages / spillage from the raw-materials storage and from

the storage of generated effluent from the proposed project.



The generated Hazardous waste will be stored on floor and also covered with

the roof.

The records on quantity of hazardous waste generation and disposal will be

maintained for each category and possibilities will be explored for minimization

and reuse.

Classification of waste

Collection, Storage, Transportation, & disposed & sell to appropriate recycler

&/or reuse.

Data Management and Reporting

Personnel Training

4.14.4 Measures for Noise To minimize the noise pollution the unit proposes the following noise control measures,

Noise suppression measures such as enclosures, buffers and / or protective

measures should be provided, if required (wherever noise level is more than 90

dB (A)).

Employees should be provided with ear protection measures like earplugs or

earmuffs. Earplug should be provided to all workers where exposure is 85 dB (A)

or more.

Extensive oiling, lubrication and preventive maintenance will be carried out for

the machineries and equipments to reduce noise generation.

Green Belt Development

4.14.5. Measures for Soil Conservation The soils are porous and there are no problems of soil erosion. Collection of rain water

in sumps is not permitted by the SPCB in case of synthetic organic chemical units in

view of the apprehension that untreated effluents may be stored.

4.14.6. Measures for Land use

Seepages, percolation of project site water / flooding of the site need to be

strictly controlled through constructions of peripheral the wall around the site.



All effluents whenever other pollutants must be controlled in such away

leakage / seepage within the project premises or within the study area.

Under no circumstances should the project allow escape of chimney

emissions that pollute ambient air quality in the study area.

As surrounding area nearby project site are mainly Single crop land, Double

crop land area, company should take care of Air & Water environment while

construction and operation phase.

As project site is altering crop land, should develop proper green belt

according to requirement of CPCB norms.

Protection & Conservation measures for crop lands should take by the

industries.

4.14.7 Ecology and Biodiversity In total area 33% of area should be allocated for greenbelt as per norms. The project is

proposed to develop greenbelt in an area of 9914.8SQM which is more than 33 % of

the total project site. Degraded land should be identified in the buffer zone area and

vegetation should be improved through line department. The specie selection should be

according to CPCB norms. Proper controlling measures will be adopted to reduce

emissions and effluents during the manufacturing process and transportation of raw

materials and products. This will minimize the effect of pollution on fauna.

4.14.8 Health & Safety measures

Provision of periodic medical checkup for all the employees is necessary first aid

facilities.

Protective equipments will be regularly checked and will be kept easily

accessible and easily workable during emergency.

Various types of fire extinguishers such as (Foam type, DCP, water, CO2 type)

will be providing inside the factory premises.



4.15 ODOUR CONTROL MEASURES

The chance of odours within premises is mainly due to

Raw materials

Storage / Handling Transportation of raw materials

Process

Raw materials transportation During reaction Drying

ETP Operations

Storage / Handling

Storage

Industry will provide adequate and proper storage facilities for all the raw materials and finished products.

Corrosive substances will be stored away from the moisture. Solid raw material will be stored in covered area and Liquid raw material will be stored in closed Horizontal / Vertical tanks. Hazardous chemicals and solid wastes will be stored away from other plant

activities. The storage yard of chemicals will be isolated and it will be equipped with all

necessary measures to control odours. 4.15.1 Handling

All the raw materials and finished products will be handled as per the standard practice.

For proper handling, company will adapt good housekeeping technology to entire shed.

To avoid any leakage or spillage of chemicals from all storage tanks, third party will inspects transfer lines, valves, fittings and every joint periodically.

4.15.2 Transportation of Raw materials

All the necessary precautions will be taken while carrying out transport of the above materials as per the Hazardous Rules of transportation.

The vehicles for transportation of raw materials and products will be parked at

specified loading facilities where there will be a provision of fire extinguishers.



The finished product will be transported by road, rail and ship route in closed

containers

4.15.3 Other sources of odour nuisance are as follows Leaks from pressurized process equipment generally occur through valves, pipe connection, mechanical seals or related equipment.

4.15.4 Control measures

To minimize & control leaks at process facilities operators carry out regular leak

detection test and repair activities.

Routine inspections of process equipment with gas detectors can be used to

identify leaks & estimate the leak rate in order to decide an appropriate corrective

action.

Proper routine maintenance of equipment reduces the likelihood of leaks.

Formaldehyde will be transferred through the closed pipe line system.

Triehanol amine will be transferred to the day tank through vacuum. But it is in

very less quantity. In that case the industry will provide mask and safety material

for that.

4.15.5 Cleaner production practices Process vessels:

Liquid raw material will be charged by pumping and closed loops and dosing will

be done by metering system to avoid odour

Double mechanical seals will be provided to the process vessels having agitator

for reduction of odour and leakages

Storage tanks

Storage tanks for products as well as raw materials will be fitted with appropriate

control devices [ Condensers with chilled water circulation systems] to avoid

possible odours / leakages

House keeping

Keep work areas clean

Keep aisles clear

Keep exits and entrances clear



Use proper waste collection containers

Cleanup spills and leaks offs any type quickly and properly

Follow up preventive predictive maintenance

ANALYSIS OF ALTERNATIVES

(TECHNOLOGY & SITE)

CHAPTER -V


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter - V Page 1

CHAPTER – V

ANALYSIS OF ALTERNATIVES (TECHNOLOGY & SITE)

Vensar Laboratories Pvt Ltd is proposed to establish Bulk Drug & Intermediates

manufacturing unit at Survey No: 32, Tupakulagudem (V) Tallapudi (M), West Godavari

(Dist.), Andhra Pradesh. (in an area of 7.00 acres (28328 SQM) having the

infrastructure facilities, land, water sources, material transportation, and power etc. are

very near to the proposed site and the site is also near to Rajahmundry. No need to

analyze any alternate site for new bulk drug and intermediate unit.

The technology proposed by Vensar Laboratories Pvt Ltd for manufacturing of bulk drug

& Intermediates is one of the best and proven technologies; hence no alternative

technology has been analyzed. Thus, for this project of Bulk Drug & Intermediates

manufacturing unit, no new or untested technology will be used and will be based on

Zero liquid Discharge.

ENVIRONMENTAL MONITORING PROGRAM

CHAPTER -VI


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter – VI Page 1

CHAPTER – VI

ENVIRONMENTAL MONITORING PROGRAM

6.1 PREAMBLE The post project environmental monitoring program serves as the key tool to keep track

on performance of mitigation measures implemented & pollution control technologies

installed to prevent impacts associated with various operations of the project.

Environmental monitoring is the repetitive and systematic measurement of the

characteristics of environmental components to test specific hypotheses of the effects of

human activity on the environment. Environmental monitoring is undertaken primarily to

determine the environmental effects of human activities, and secondarily to increase

understanding of cause-effect relationships between human activity and environmental

change. Thus, environmental monitoring is the effective observation of site conditions

and work activities; and identification of potential non-compliance situations and

initiation of corrective or remedial actions. Monitoring is as important as that of control of

pollution, since the efficiency of control measures can only be determined by

monitoring.

6.2 MONITORING PROGRAM From the monitoring point of view, the important components are air, water, soil, noise

and occupational health & safety. Regular monitoring will be carried out by NABL

approved laboratory. Environmental monitoring program after the proposed project is

given in following Table 6.1. TABLE- 6.1: THE DETAILS OF THE MONITORING PROGRAM

S. No Type of Monitoring

Location of Monitoring

station

Frequency of

Sampling Duration of Sampling Instrument Parameters to

be test

1 Ambient Air 3 Places at 120o angle

Once in a month

8 hrs/24 hrs RDS PM10, SO2, NOX

2

Work room concentration

Production Block, Store rooms, Solvent Yard

Once in 3 Months

--- Personal Sampler

VOC’S & Solvents

3 Stack Monitoring

Boilers, D. G. Sets, Scrubber

Once in a month

--- Stack Monitoring

PM10, SO2, NOX and Scrubbing



vents Instrument gases.

4

Noise Levels D. G. Sets, Compressors, Chillers, Boiler section, Production block, Admin. block, ETP area, Open area etc.

Once in a month

--- Noise meter

Day – Night Noise levels in Leq

5

Effluent Raw HTDS & LTDS effluent, Condensate, Treated wastewater

Daily --- Lab

Physical and Chemical Parameters

6 Ground water Nearest Bore well

Once in six months

---

7 Solid Waste Sludge from Process, ETP

Once in six months

---

All the above observations will be complied and documented by the EMC to serve the

following purposes.

Identification of any environmental problems that are occurring in the area.

Initiating or providing solution to those problems through designed channels and

verification of the implementation status

Controlling activities inside the plant, until the environmental problem has been

corrected.

Suitably responds to emergency situations

The industry will engage recognized laboratories to carry out all necessary monitoring

parameters. Qualified staff will be appointed for the purpose of Operation and

maintenance of the pollution control facilities. Stand-by facilities will be provided to all

the facilities so as to ensure fail proof treatment.

6.3 INFRASTRUCTURAL REQUIREMENT

Looking to the Zero Effluent Discharge by complete evaporation of collected and

equalized effluent, there is no need to establish full fledge laboratory for ETP. However,

unit will regularly check pH of the raw effluent. Flow meter will be provided at the ETP



(on feed line of Evaporator) for regular monitoring of wastewater quantity. In addition to

this, same as the current practice, regular monitoring will be carried out for wastewater,

gaseous emission, fugitive emission and noise by NABL approved laboratory as

proposed in monitoring program.

6.3.1 LIST OF INSTRUMENTS FOR ENVIRONMENTAL MONITORING A. High Volume Sampler (Respirable Dust Sampler)

Blower : 1.5 m3 / min capacity with adapter for uniform suction

through filter, cyclone separator and arrangement to

sample gases.

Voltage Stabilizer : A properly calibrated manometer assembly for the

determination of flow rate through filter paper.

Rota meter : Calibrated (0-5lpm) for maintaining flow rate for

gaseous sampling.

Main Housing : Rectangular main housing (29 cm x 36 cm)

B. Noise Monitoring

Noise levels in the work space environment will be monitored periodically. If any

deviation is observed necessary corrective measures will be taken. Monitoring noise

level is essential to assess the efficacy of maintenance of schedules undertaken to

reduce noise levels and noise protection measures. A good quality sound pressure level

meter is essential for this purpose. This work can be handled by plant authorities

themselves or by hiring services. Noise surveillance is for the benefit of the workers well

being and to keep track of machine wear.

C. Monitoring Of Effluents Streams

The quality of the blow down water from the boiler and other effluents from the plant

would be periodically analyzed. These data will be documented and compared against

the design specifications. Necessary corrective action will be promptly taken. All the

raw effluents will be sent to ETP and analyzed meticulously as well as treated effluents.



After meeting the discharge standards for on land for irrigation treated effluent will be

used for Greenbelt development.

The following equipments are required for this purpose.

pH meter : 0-14 + 0.1 pH units

TDS meter : Calibrated

Filtration Unit : Capable of holding glass fiber filters

Water bath : With regulator

Incubator : 27o C+1oC

Heating mantle : With regulator for COD

Separating Funnels : for oil and grease

Muffle furnace : 650o C

Single pan balance : Max. 150gms capacity (Accuracy 0.1mg)

Unit will setup First Aid Centre inside the plant premises. Unit will make necessary tie-

up with nearby hospital for the medical assistance in case of any emergency. Medical

officer are appointed for the periodical health check-up of the employees. Periodical

health check-up reports of all the employees will be maintained. In addition to the

above, unit will maintain health records per the factory act.

6.4 CORPORATE ENVIRONMENTAL RESPONSIBILITY

Unit not only carries out business but also understands the obligations towards the

Environment. The unit believes in sustainable development and equally concern about

environment preservation and pollution control. Unit will establish a well organized

Environmental Management Cell (EMC) which performs all the environmental

management activities. The unit will lay down Environment, Health & Safety Policy and

will be approved by its Managing Director.

The EHS Policy prescribes to comply with statutory norm with regards to the

Environment, Health & Safety, to prevent pollution by adopting cleaner production



techniques, identification and management of operational hazards and risks and to

ensure the safety of people. All employees at each cadre of the unit will be educated

about the EHS Policy of the company and policy will be posted at various prominent

places in the unit. It is suggested to revise EHS policy for standard operating

procedures to bring into focus any infringement / deviation / violation of the

environmental or forest norms/conditions with regards to the Environment, Health &

Safety and to take further corrective actions. Hierarchical system and administrative

order of the company to deal with the environmental issues and for ensuring total

environmental compliance are described in the subsequent topics with relevant

headings.

TABLE 6.2: CORPORATE ENVIRONMENTAL RESPONSIBILITY

S. No CONDITIONS COMPLIANCES

A

Does the company have a well laid down Environmental policy approved by its board of directors? If so, it may be detailed in the EIA report

Company will be adopted Environmental policy in operational phase

B

Does the Environmental policy prescribes for standard operating process / procedures to bring into focus any in fragment/deviation/violation of the Environmental or forest norms/conditions If so, it may be detailed in the EIA report

We will establish Environmental policy and standard operating procedures during operational phase

C

What is the hierarchical system or administrative order of the company to deal with the environmental issues and for ensuring compliances with the EC conditions. Details of this system may be given

The details are given below under heading ‘ENVIRONMENTAL MANAGEMENT CELL’

D

Does the company have a system of reporting of non compliance / violations of environmental norms to the board of directors of the company and / or shareholders or stake holders at large? This reporting mechanism should be detailed in the EIA report.

Non compliance reports are will be communicated to all directors in a systematic manner



6.5 ENVIRONMENTAL MANAGEMENT CELL All the project activities are monitored to ensure the appropriate implementation of all

environmental mitigation activities and to identify areas where environmental

management plan compliance is not satisfied. For effective implementation of the

monitoring program, it is also necessary to have a permanent organizational set-up.

Unit will set-up permanent environmental management cell (EMC) for the effective

implementation and monitoring of environmental management system. The unit will

assign responsibility to officer from various disciplines and cadres to perform and co-

ordinate the activities concerned with management and implementation of

environmental control measures. The environmental management cell (EMC) set-up by

unit is given here below in Figure 6.1

FIGURE 6.1: ENVIRONMENTAL MANAGEMENT CELL

General Manager of the unit is responsible for total environmental management. Overall

activities performed by EMC are presented below and details of responsibilities to be

given to each officer of the EMC are given in Table 6.3.

Collect information from regular monitoring and create database.

Analyze the data and decide thrust area.

Carry out “project” in each thrust area to arrive at practical solutions to

environmental problems.

Discuss the reports of study on environment and disseminate the information.

Director

General Manger

Officer - EHS

Supervisors & Operators



Work out action plan for implementation of the recommendations made in the

report.

Prepare Management Information System (MIS) reports and budget for

environment management program.

To deal with the environmental issues and for ensuring compliance with the

conditions prescribed by SPCB.

Non compliance / violation of environmental norms, if any are reported to

Managing Partner and immediate required action is taken.

Efficient operation and regular monitoring of environmental management

systems

Prepare budget for environmental monitoring program

TABLE 6.3: RESPONSIBILITIES OF EMC

S. No Name

& Designation

Responsibilities

1 Director Approve environment policy and give directions to succeeding component of the cell

2 General Manager

Responsible for overall environmental management. Regularly coordinate with Officer-EHS and take feedback regarding all the activities performed under EMC, keep aware the Director of the unit about all the activities performed under EMC, any major issue/accidents / incident take place, any noncompliance / violation of environmental norms

3 Officer-EHS

Establish EHS Policy, Development EHS SOP, EHS Plan, Manual, Evolutes EHS program & training, Legal complacencies of SPCB & other Authorities. Execute and follow-up for routine monitoring, cleaning and maintenance work of environmental Management systems. Observe regularity, discipline and working strength of ETP operator. Property Loss Prevention activities, Work permit, Plant equipment changes, Mock rill activity, Safety Inspection & audit work, EHS Incidents/Accident investigation, Employee observations/near misses along with corrective action, Develop safety Committee & take quarterly its meeting Review & compliance report. Reporting to the General Manager about all the activities performed under EMC, any major



issue/accidents/incident take place, any noncompliance/ violation of environmental norms

4 Supervisors

& Operator

To coordinate with production department, Utility, Engineering department to run ETP smoothly, carry out daily effluent analysis & take necessary actions if required & maintain & update all documents & records on daily basis, Routine cleaning & maintenance of ETP, Maintain minimum stock of required chemicals / materials, Give indent for spare components and follow up for it, maintain hazardous waste storage area in good condition & Record of it, Observe regularity, discipline, working strength of helpers.

6.6 ADMINISTRATIVE ACTIONS & DOCUMENTATION 6.6.1. Data Analysis All environmental monitoring data are stored as computer database by the

Environmental Management Cell (EMC) for proper storage, retrieval and interpretation

of the same. A regular database format is maintained to keep a track of monitored

parameters and causes are identified in case of non-conformity with the permissible

limits.

6.6.2. Reporting Schedules

Voluntary reporting of environmental performance with reference to EMP is undertaken.

General Manager and Officer-EHS co-ordinate all monitoring programs at site and data

generated will be submitted regularly to the statutory agencies. Frequency of reporting

is as per the requirement of SPCB and MoEF&CC.

6.6.3. Environmental Monitoring Expenditure

The monitoring and evaluation process requires extensive surveys and primary

data collection, either to establish the baseline or to measure changes. In order to

respond management needs for carrying out environmental monitoring, a contingency

budget is required. Cost towards environmental monitoring will be about Rs. 2.00 Lakhs.

ADDITIONAL STUDIES

CHAPTER -VII


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter - VII Page 1

CHAPTER – VII

ADDITIONAL STUDIES, RISK ASSESSMENT & DISASTER MANAGEMENT REPORT

The proposed project for the manufacturing of Synthetic Organic chemicals (Bulk

Drugs & Intermediates) by VENSAR LABORATORIES PVT.LTD.is covered under

Category- A of the EIA Notification – 2006.Public Consultation was conducted for

this project on 29.05.2009

ADDITIONAL STUDIES In order to support the environment impact assessment and environment management plan, following additional studies have been included in this report.

Risk assessment

Occupational Health

Disaster management plan

SCOPE OF THIS STUDY

The QRA study in this report has been conducted considering the Terms of

References (TORs) given by Expert Appraisal Committee of MoEF&CC for

Environment Clearance (EC).

The study has been carried out with a view to comply all TOR points



RISK ASSESSMENT & DISASTER MANAGEMENT RISK ASSESSMENT

7.1. INTRODUCTION TO RISK ASSESSMENT

VENSAR LABORATORIES PVT.LTD.handles various chemicals, some of which

are hazardous in nature by virtue of their intrinsic chemical properties or their

operating temperatures or pressures or a combination of them. Fire, explosion,

toxic release or combinations of them are the hazards associated with industrial

plants using hazardous chemicals. More comprehensive, systematic and

sophisticated methods of Safety Engineering, such as, Hazard Identification and

Qualitative /Quantitative Risk Assessment have been developed to improve upon

the integrity, reliability and safety of industrial plants, the same has been discussed

in detail under their respective headings. OBJECTIVES OF RISK ASSESSMENT

Risk analysis follows an extensive hazard analysis. It involves the identification and

assessment of risks the neighboring populations are exposed to as a result of

hazards present. This requires a thorough knowledge of failure probability, credible

accident scenario, vulnerability of population etc., much of this information is difficult

to get or generate. Consequently, the risk analysis is often confined to maximum

credible accident studies.

It provides basis for:

The type and nature of its on-site and off-site emergency plan

The types of safety measures required.

7.2. IDENTIFICATION OF HAZARDS

Hazard identification is carried out to ascertain the controls required and

available in order to mitigate the risk of exposure to the hazards. This would

substantially help in overcoming costly errors and prolonged delays that may

be caused due to the design changes that may be required on a later date.

Hazard assessment is carried out at the equipment design stage and the

control / mitigation measures are put in place overcome them to avoid costly

errors at a later stage.

Hazard assessment in our plant is carried out examining the, material storage,

type of operations, locations to find out the facilities in place to overcome the

risks of exposure to the hazards.



After a critical analysis of the chemicals used, stored, defined safe operating

procedures and the different manufacturing processes, the following table lists

the safety measures / installations in place and mitigation measures to

overcome the hazards.

Following are the Hazards identified in project activities:

Fire Hazards Spillage of chemicals Explosion Hazards Toxic gas release Noise



TABLE: 7.1.AREA WISE IDENTIFIED HAZARDS, PRECAUTIONS TAKEN WITH MITIGATION MEASURES.

S.NO

AREA

IDENTIFIED

HAZARD

SEVERITY &

NO. OF PERSONS EXPOSED

PRECAUTIONS TAKEN

MITIGATION MEASURES

1] RM Storage area

Spillage of chemicals

Low to medium 4 persons

1. Approved layout as per legal / GM requirements. 2. Flame proof electrical fittings installed 3. Chemicals stored in safe Containers with secondary containment to prevent spillages. 4. Storage quantity is limited 5. Storage area is well ventilated by a forced air ventilation system. 6. Material accessed only by authorized personnel using mechanized systems 7. Double door entry to ensure a clean atmosphere. 8. Body provided showers for decontamination.

1. Area is cordoned off.

2. Emergency control center is Informed. 3. Information is given to the declarer of emergency on the scale of leakage. 4. Emergency Response teams are kept on alert for swift response. 5. All hot works being carried out in the surrounding areas are stopped 6. Personnel working in the area are evacuated.



S.NO

AREA

IDENTIFIED

HAZARD

SEVERITY &


PRECAUTIONS TAKEN

MITIGATION MEASURES

9. Personnel are provided with full body protection suits and nose masks to prevent exposure to chemicals. 10.Fire hydrant system with hydrant points with hose reels and nozzles installed to mitigate fire hazards 11.Fire extinguishers deployed adequately 12. Fully fledged medical center /arrangements 13. Periodical occupational health checks to personnel working in the area to assess health effects, if any.

7. Spilled powders are collected in vacuum cleaners. 8. The spillage is cleared and the area is made fit work



S.NO

AREA

IDENTIFIED

HAZARD

SEVERITY &


PRECAUTIONS TAKEN

MITIGATION MEASURES

2]

Solvent drums Storage area

Fire & Explosion

Medium to Low 2 persons

1. Storage facility located in isolated area 2. Natural ventilation for supply of fresh air 3. No electrical fittings in the area to prevent any fire hazard. 4. No electrical gadgets or items capable of generating static electric charges permitted inside the area. 5. Personnel are trained about Do’s & Don’ts during emergency. authorized personnel on 6. No heat sources are permitted near the facility. 7. Hot work is controlled through a work permit system 8. Room kept under lock and key with access to authorized personnel only.


2. Hot work being carried out in the vicinity is stopped to prevent accidental spread of fire. 3. Personnel working in the area are evacuated 4. Emergency control center is informed 5. Information is given to the declarer of emergency on the scale of leakage. 6. Emergency Response teams are kept on alert for swift response. 7. The spillage is cleared and the area is made fit work



S.NO

AREA

IDENTIFIED

HAZARD

SEVERITY &


PRECAUTIONS TAKEN

MITIGATION MEASURES

9. Storage quantity is limited and material is handled by trained and authorized personnel. 10. Mechanical foam type fire is provided to mitigate fires 11. Fire hydrant system with hose reels are provided in the vicinity



S.NO

AREA

IDENTIFIED

HAZARD

SEVERITY &


PRECAUTIONS TAKEN

MITIGATION MEASURES

3]

Production Block

Spillages / Fire /Explosion


1.Flame proof electrical fittings installed

2. Freight lift installed for movement of material 3. Material stored at production blocks in safe containers for batch charging with secondary containment to prevent spillages. 4. Earthing and bonding carried out for all reactor vessels and pipelines 5.Nitrogen lines are provided to reaction vessel to create inert atmosphere inside the reactor to avoid fire and explosion 6. Work permit system implemented for hazard assessment in case of any hot work / height work . 7. Work permit system implemented for hazard assessment in case of any hot work / height work.


2. Power supply is cut off to the area to prevent accidental fire. 3. All hot work carried out in the vicinity is stopped. 4. Emergency control center is informed. 5. Information is given to the declarer of emergency on the scale of Leakage / Accident 6. Emergency Response teams are kept on alert for swift response. 7. Personnel working in the area are evacuated. .



S.NO

AREA

IDENTIFIED

HAZARD

SEVERITY &


PRECAUTIONS TAKEN

MITIGATION MEASURES

8. Manufacturing area is ventilated by a forced air ventilation system. 9. Fire hydrant system with hydrant points with hose reels and nozzles installed to mitigate fire hazards 10. Fire extinguishers deployed adequately 11. Emergency exit glass door with glass breaking hammer provided for safe escape in case of any emergencies. 12. Eye wash fountain / Body shower provided for decontamination.



S.NO

AREA

IDENTIFIED

HAZARD

SEVERITY &


PRECAUTIONS TAKEN

MITIGATION MEASURES

4]

Boiler House

Fire / Explosion

Low to medium Approx 2

1. All requirements specified under Boiler Act and Boiler licensed is adhered to. 2. All electrical fittings are of flame proof type. 3. Entry restricted only to trained and authorized personnel to work in the area. 4. Fire extinguishers are positioned at different locations in case of any emergencies. 5. No material storage is permitted in the area.

1. Shutting down the plant, declaring the emergency. 2. Electrical supply is isolated. 3. Type of emergency is informed to the emergency declarer/ central authority. 4. Emergency response teams are kept on alert for swift action. 5. Movement of personnel and vehicles are prohibited.



S.NO

AREA

IDENTIFIED

HAZARD

SEVERITY &


PRECAUTIONS TAKEN

MITIGATION MEASURES

6. Area is well ventilated and illuminated for safe working. 7. 24 x 7 manning of the area for monitoring the operation. 8. All maintenance /repair works are carried out after issuing work permits and under constant supervision of experts. 9. Periodical cleaning of soot in furnace to prevent formation of explosive mixtures. 10. Monitoring the boiler operational parameters and periodical cleaning 11. Checking of boiler internals to prevent accidents. 12. Signages are displayed to inform personnel about the hazards present in the area

6. Area is well ventilated and illuminated for safe working. 7. 24 x 7 manning of the area for monitoring the operation.



S.NO

AREA

IDENTIFIED

HAZARD

SEVERITY &


PRECAUTIONS TAKEN

MITIGATION MEASURES

5]

Diesel Generator

Noise & Fire

Low to medium 1-2 persons

1. Noise abatement thru’ modular acoustic paneling of D.G sets 2. Secondary containment to prevent Diesel leakage from day tanks. 3. Adequate no. of fire extinguishers is kept to handle emergency . 4. Entry access to the area controlled

1. Information is given to Emergency control center. 2. Power supply is cut off to the storage area to prevent accidental fire. 3. All hot work around the area is stopped and the area is cordoned off . 4. The concerned maintenance personnel carry out repairs to mitigate the leakages. 5. Emergency Response Team is kept on alert for swift response. 6. Periodical occupational health checks to personnel working in the area to assess exposure to noise.



S.NO

AREA

IDENTIFIED

HAZARD

SEVERITY &


PRECAUTIONS TAKEN

MITIGATION MEASURES

6]

Electrical sub stations

Electric shock / fire


1. Layout confirm to legal requirements specified under Indian Electrical Rules. 2. Entry restricted to licensed and authorized personnel only. 3. Earthing provided for leakage of stray currents. 4. Electronic mimic panels installed for fault indication at the entry of the sub-station. 5. Insulating rubber mats confirming to IS 15652:2006 provided in front of all electrical switchgear. 6. Periodical inspection and maintenance carried out to ensure good health of the equipment. 7. CO2 / DCP fire extinguishers deployed to handle emergency fires

1. Information is given to Emergency control center. 2. Power supply is cut off from incoming source. 3. Electricity supply company is alerted for cut off power supply in case of major risks 4. All hot work around the area is stopped and the area is cordoned off. 5. The concerned maintenance personnel carry out repairs to restore normalcy. 6. Emergency Response Team is kept on alert for swift response



S.NO

AREA

IDENTIFIED

HAZARD

SEVERITY &


PRECAUTIONS TAKEN

MITIGATION MEASURES

7]

Hazardous waste storage room

Fire

1Person

1. Storage shed in an isolated location. 2. Conditions specified in hazardous waste authorization issued by SPCB implemented. 3. Compatible wastes are stored in separate enclosures 4. Layout provides adequate ventilation and illumination 5. Secondary containment provided to prevent leakages / spillages 6. Storage quantity is limited. 7. Periodical disposal of accumulated waste to authorized landfills. 8. Flame proof electrical fittings installed to prevent fire / explosion hazards

1. Information is given to Emergency control center. 2. Power supply is cut off from incoming source. 3. All hot work around the area is stopped and the area is cordoned off. 4. The concerned maintenance personnel carry out repairs to restore normalcy



S.NO

AREA

IDENTIFIED

HAZARD

SEVERITY &


PRECAUTIONS TAKEN

MITIGATION MEASURES

9. Eye wash / body shower is provided for decontamination in case of spillage on body parts. 10. PPE box is equipped with gum boots, splash proof safety goggles, aprons for use during handling of chemicals. 11. Access to the area restricted to authorize personnel only. 12. Fire hydrant point with hose reels provided for fire mitigation

5. Emergency Response Team is kept on alert for swift response. 6. Support of external agencies is sought in case situation poses major risks and is not controllable by in-house infrastructure



TABLE: 7.2.RAW MATERIALS INVENTORY [RAW MATERIALS - MAXIMUM INVENTORY, MODE OF STORAGE, HAZARDS, HANDLING PRECAUTIONS & HAZARD MITIGATION PLAN [EMERGENCY PREPAREDNESS]

S.NO NAME OF THE CHEMICAL

PHYSICAL STATE

MODE OF STORAGE

MAX. INVENTORY IN

TONS. NATURE OF

HAZARD

1 9H-Carbazol-4-ol Solid Fibre Drums 1.500 Harmful

2 (Chloromethyl) oxirane Liquid HDPE Drums 2.000 Corrosive

3 Sodium sulfate Solid Fibre Drums 0.200 ---

4 (2-methoxyphenoxy)ethylamine Liquid HDPE Drums 1.000 Flammable

5 Sodium chloride Solid PP Bags 0.200 Irritant

6 5-Cyanophthalide Solid Fibre Drums 1.000 Toxic

7 4-fluorophenylmagnesium chloride Liquid HDPE Drums 0.500 Flammable

8 (Dimethylamino)propyl magnesium chloride Liquid HDPE Drums 0.500 Flammable

9 Hydrochloric acid Liquid HDPE Carboys 2.000 Corrosive

10 Hydrogen bromide Liquid HDPE Carboys 0.250 Corrosive

11 5-chloro-2-benzoylpyrrole Liquid HDPE Drums 0.500 Corrosive

12 Methyl-gama-methoxy butanonate Liquid HDPE Drums 0.500 Flammable

13 Sodium hydroxide Solid PP Bags 0.500 Corrosive

14 Tromethamine Solid Fibre Drums 0.500 Corrosive



S.NO NAME OF THE CHEMICAL

PHYSICAL STATE

MODE OF STORAGE

MAX. INVENTORY IN

TONS. NATURE OF

HAZARD

15 2-(1-carboxy-ethylamino)-4-phenyl-butyric acid ethylester Solid Fibre Drums 1.000 Corrosive

16 (cis,endo)-octahydro-cyclopenta[b]pyrrole-2(s)-carboxylic acid hydrochloride

Solid Fibre Drums 1.000 Corrosive

17 Triethylamine Liquid HDPE Drums 1.500 Flammable

18 5% Pd/Activated carbon Solid Fibre Drums 0.020 Flammable

19 4-(3,4-dichlorophenyl)-3,4-dihydro-N-methyl-1(2H)-naphthalenimine

Solid Fibre Drums 1.000 Harmful

2 Sodium boro hydride Solid MS Drums 0.100 Flammable

21 D(-) Mandelic acid Solid Fibre Drums 0.300 Corrosive

22 Dimethylnaphthalen -1-yl amine Liquid HDPE Drums 0.500 Flammable

23 1-Chloro-6,6-dimethylhept-2-en-4-yne Liquid HDPE Drums 1.000 Flammable

24 Potassium carbonate Solid PP Bags 0.500 Irritant

25 Dimethylamine .hydrochloride Solid Fibre Drums 2.000 Corrosive

26 Formaldhyde Liquid HDPE Drums 1.500 Corrosive

27 Magnesium Solid Fibre Drums 0.250 Combustible

28 m-Bromoanisole Liquid HDPE Drums 0.500 Flammable

29 2-Dimethylaminomethyl-cyclohexanone Solid Fibre Drums 1.000 Flammable



SOLVENTS

S.NO NAME OF THE SOLVENT

PHYSICAL

STATE MODE OF STORAGE

MAX. INVENTORY

IN TONS. NATURE OF

HAZARD NFPA RATING

1 Methanol Liquid MS Tank 15.000 Flammable H: 1 F: 3 R: 0 2 Ethyl acetate Liquid HDPE Drums 4.000 Flammable H: 1 F: 3 R: 0

3 THF Liquid MS Drums 4.000 Flammable H: 2 F: 3 R: 0

4 Acetone Liquid MS Tank 15.000 Flammable H: 1 F: 3 R: 0

5 Ethanol Liquid HDPE Drums 3.000 Flammable H: 2 F: 3 R: 1

6 IPA Liquid HDPE Drums 4.000 Flammable H: 1 F: 3 R: 0

7 Toluene Liquid MS Tank 15.000 Flammable H: 2 F: 3 R: 0

TABLE: 7.3.LIST OF FINISHED PRODUCTS LIST OF PRODUCTS

S.NO.

PRODUCT NAME

PHYSICAL STATE

QUANTITY IN KGS /MONTH

MODE OF STORAGE

NATURE OF HAZARD

1 Carvedilol Solid 5000.00 Fibre Drums Harmful 2 Citalopram Hydro Bromide Solid 2000.00 Fibre Drums Harmful 3 Ketrolac tromethamine Solid 5000.00 Fibre Drums Harmful 4 Ramipril Solid 5000.00 Fibre Drums Harmful 5 Sertraline Hydrochloride Solid 5000.00 Fibre Drums Harmful 6 Terbinafine Hydrochloride Solid 4000.00 Fibre Drums Harmful 7 Tramadol Hydrochloride Solid 5000.00 Fibre Drums Harmful

Above products will be manufactured on campaign basis, only two products will be in production at any given time



HANDLING PRECAUTIONS OF CHEMICALS

Use in a closed system under argon or nitrogen. Do not get in eyes, on skin or clothing. Do not breathe vapors or mist. Store in a cool place. Keep container closed. Keep away from sources of ignition, water, air, acids and oxidizing agents In case of fire, do not use water or carbon dioxide

EMERGENCY PREPAREDNESS

OSEP Training & Awareness



7.3. SAFE PRACTICES [HANDLING, STORAGE, TRANSPORTATION AND UNLOADING OF CHEMICALS] Drums

Solvents will be transferred from the drums to the day tank situated at the production

block with the help of leak proof drum pumps / AOD pumps /Vacuum through pipe

lines. From day tank to reaction vessel unloading by gravity.

Storage Tanks

Solvent will be transferred to the day tank situated at the production block with the

help of mechanical seal pump through pipe lines from the tank, from day tank to

reaction vessel unloading by gravity.

Tank is connected to chilled water circulated condenser with reflux system

Measures to Avoid Evaporation

Keep containers tightly closed.

Keep away from heat, sparks, and flame

Keep away from sources of ignition

Store in a cool, dry, well ventilated area away from incompatible substances

Safety Systems

Designated areas with proper indication & safety sings

Double earthling systems

Flame arrestor to the vent

Flame proof transferring pumps

Handling precautions/sop protocol

Pressure Gauges

Level indicators

Flame proof lighting to storage yard

TRANSPORTATION / UNLOADING

Highly inflammable chemicals will be transported by road. Therefore, adequate

safety precautions for transportation are followed. During transportation of hazardous

chemicals, MSDS & TREM card will be provided to driver. As per Motor Vehicle

Rules, PESO rules and Factory Rules all safety precautions will be followed during

transportation of hazardous chemicals.



The following safety precautions are suggested during transportation of toxic,

inflammable and corrosive chemicals in tankers, while loading and unloading,

transportation and meeting the emergencies arising out of leakages and spillages of

hazardous materials:

Park the vehicle at designated place.

Stop the engine.

Check-up spark arrester.

Provide earthing to tanker securely.

Ensure that fireman is available near the place with proper equipment‘s.

Connect the piping properly

Before start unloading, check that, there should not be any leakage.

In case of leakage, immediately attend the leakages & rectify it.

After unloading is over, close the lid properly.

Vehicle to be started only after removal of all pipelines connected with

tanker.

7.4. SAFETY INSTRUCTIONS FOR TRANSPORTATION OF HAZARDOUS

MATERIALS

The name of the chemical along with pictorial sign denoting the

dangerous goods should be marked on the vehicle and the packing

material.

The name of the transporter, his address and telephone number should

be clearly written on the road tanker and on the vehicle.

The tanker or vehicle should not be used to transport any material other

than what is written on it.

Only trained drivers and cleaners should transport hazardous chemicals.

The transporter and the manufacturer must ensure the safe transportation

of the material.

The Tanker / Vehicle should be checked for its fitness and safe condition

before loading.

During loading and unloading, the tanker/vehicle should be braked and

isolated against any movement, while loading/unloading, use safety

appliances.



The tanker / vehicle should not be overloaded beyond the weight

permitted by R.T.O.

Check for leakages from the line connections / containers before starting

and Stopping the filling operations.

Drive the vehicles carefully, especially in crowded localities and on Bumpy

roads.

Do not apply sudden break.

The tanker / vehicle should not be parked for long time on the way and especially in crowded places. Park the vehicle away from residential areas 7.5. SPILL CONTROL

For all plants spill control procedures will be displayed. Spillage shall be

controlled as per concerned spill control procedure.

Unprotected personnel up wind will be kept up wind.

Like any spilled materials to contain. Absorb spilled liquid by dry absorbent

clay or sawdust.

Collect most of the contaminated absorbent with shovel for further

disposal/incineration.

If spill of material directly on the ground, dig up and remove saturated soil

for disposal/incineration.

Inactivate poisonous chemical with suitable method.

7.6. IDENTIFICATION OF HIGH RISK AREAS It is observed that the storage areas pose fire/explosion hazards which may lead to

major accident event. In the process areas it is observed that inventories of

chemicals are very low & so there are not deemed to pose major off-site hazards.

Thus, the quantitative risk assessment studies are limited to unit and some extent in

vicinity. 7.7.1 MODES OF FAILURE Storages system can fail in different ways depending on the materials stored,

storage conditions & may involve systems in their vicinity. Conditions such as over

filling, over pressure, missile, lightening or bomb attack, earthquake & resultant

replier or release scenarios have been identified. Outcomes of such incidents are



determined by presence of ignition either immediate or delayed. As can be seen

depending upon modes of failure different scenarios are possible viz:

1. Continuous release 2. Instantaneous release This may be of gas / liquid depending upon type of material stored/released & its

characteristics. More examples, a liquid boiling at ambient conditions, will

immediately be converted to gas upon exposure to atmosphere.

An instantaneous release is any release occurring for a period less than 15 seconds.

Failure mode responsible for instantaneous releases may be catastrophic failure of

chemical storage tank / drum. For an instantaneous gas release important

parameters are release height & quantity released whereas for instantaneous liquid

release, important parameters are amount spilled, spill area & pool temperature,

evaporation rate, vapour mass etc. Continuous release occurs when the material is

released over a period greater than 15 seconds. For a continuous gas release,

important parameters include height of leak above ground, emission rate & total time

of release. For continuous liquid release important parameters are spill rates,

duration, area & pool temperature, evaporation rate and vapor mass or Gas mass. 7.7.2 MAXIMUM CREDIBLE ACCIDENT ANALYSIS AND ITS MITIGATION MEASURES A Maximum Credible Accident (MCA) can be characterized as the worst credible

accident. In other words: an accident in an activity, resulting in the maximum

consequence distance that is still believed to be possible. A MCA-analysis does not

include a quantification of the probability of occurrence of the accident. Another

aspect, in which the pessimistic approach of MCA studies appears, is the

atmospheric condition that is used for dispersion calculations. The Maximum

Credible Loss (MCL) scenarios have been developed for the Facility. The MCL

cases considered, attempt to include the worst “Credible” incidents-what constitutes

a credible incident is always subjective. Nevertheless, guidelines have evolved over

the years and based on basic engineering judgment, the cases have been found to

be credible and modeling for assessing vulnerability zones is prepared accordingly.

The objective of the study is Emergency planning, hence only holistic & conservative



assumptions are used for obvious reasons. Hence, though the outcomes may look

pessimistic, the planning for emergency concept should be borne in mind whilst

interpreting the results.

In Consequence analysis, geographical location of the source of potential release

plays an important role. Consideration of a large number of scenarios in the same

geographical location serves little purpose if the dominant scenario has been

identified and duly considered.

The Consequence Analysis has been done for selected scenarios by ALOHA

The details of software used for MCA analysis are described below.

The mathematical model is based on the Emergency Response Planning Guidelines (ERPGs) which gives Toxic Levels of Concern (LOCs) to predict The area where a toxic liquid concentration might be high enough to harm People.

ALOHA models key hazards-toxicity, flammability, thermal radiation (Heat), and over pressure (expansion blast force)-related to chemical releases that result in toxic gas dispersion, fire and/or explosion 7.7.3. CONSEQUENCES ANALYSIS From the solvents toluene have been taken for the consequences analysis

considering their hazardous nature. Storage condition and threshold value of

Toluene and other properties are given in tables

TABLE: 7.4. STORAGE DETAILS OF SOLVENTS S.NO

SOLVENT NAME

PHYSICAL FORM

TYPE OF STORAGE

SIZE OF STORAGE UNIT

MAXIMUM STORAGE CAPACITY

STORAGE PRESSURE KG/CM2

STORAGE TEMP. ºC

1 Acetone Liquid Tank 20KL 15 TONS ATM RT 7.7.4. POSSIBLE ACCIDENT SCENARIO Different possible ways of occurrence of any accidents due to storage/usage of

above solvent is prescribed here below

SITE DATA

Building Air Exchanges Per Hour: 10

CHEMICAL DATA

Chemical Name: ACETONE



Molecular Weight: 58.08 g/mol

AEGL-1 (60 min): 200 ppm



LEL: 26000 ppm

UEL: 130000 ppm

Ambient Boiling Point: 56.3° C

Vapor Pressure at Ambient Temperature: 0.13 atm

ATMOSPHERIC DATA: (MANUAL INPUT OF DATA)

Wind: 1.5 meters/second from se at 3 meters

Ground Roughness: open country

Air Temperature: 410 C

Relative Humidity: 50%

SOURCE STRENGTH

Leak from hole in vertical cylindrical tank

Flammable chemical is burning as it escapes from tank

Tank Diameter: 2 meters

Tank Length: 6.5 meters

Tank Volume: 20.4 cubic meters

Tank contains liquid

Internal Temperature: 35° C

Chemical Mass in Tank: 15000 kilograms

Tank is 95% full

Circular Opening Diameter: 2 inches

Opening is 1 feet from tank bottom

Max Flame Length: 10 meters

Max Burn Rate: 93 kilograms/min



Total Amount Burned: 5,477 kilograms

Note: The chemical escaped as a liquid and formed a burning puddle.

The puddle spread to a diameter of 6.2 meters.

THREAT ZONE

Threat Modeled: Thermal radiation from pool fire

Orange: 15 meters --- (5.0 kW/(sq m) = 2nd degree burns within 60 sec)

Yellow: 23 meters --- (2.0 kW/(sq m) = pain within 60 sec)

7.8. OCCUPATIONAL HEALTH

Hazardous and toxic substances are defined as those chemicals present in the work

place which are capable of causing harm.

[In this definition the term chemicals include dust, mixtures and common materials-

solvents.]

For handling hazardous chemicals and to take care of employee’s health,

and predictive maintenance looking to the nature of hazardous chemicals



being handled/processed. All the equipments in the plant areas shall be

inspected / tested by an outside agency.

The various safety equipments like breathing apparatus and critical

instrumentation provided on various equipments are inspected and tested

frequently to ensure their operability all the time. Besides, all the first aid, fire

fighting devices are also being inspected, tested and maintained by a

competent third party and kept all the time in ready to use condition.

Health of all the employees in plant area is regularly monitored by outside

physician. If any abnormality is found necessary treatment is also being

given time to time. Necessary history cards, records are also be maintained

which is up-dated time to time.

Common Hazards

Physical such as ventilation, poor illumination, noise, extreme temperature,

humidity and radiation.

Biological such as variety of pathogenic bacteria and parasites.

Chemical due to hazardous gases and dusts.

Ergonomic.

Industrial Hygiene Monitoring

Industrial hygiene monitoring is to located and identify source of exposure in

the workplace so that they can be corrected and to quantify the exposure of

employees to chemicals in the air.

Air monitoring is conducted by industrial hygienists or other trained personnel.

Occupational Health Monitoring System

A. Air samples

Locations of samples – air samples are generally collected in one or three

locations:

At the breathing zone of the worker [Personal sample]

In the general room air [Area sample]

At the operation which is generating the hazardous substance [Area

sample]

Lengths of samples – Air samples are generally collected for two lengths of time.



Grab samples [instantaneous] measure conditions at one moment in time

and can be likened to a still photograph. They give only a picture of

conditions at one place at one instant in time.

Continuous Samples [range from twenty minutes to 8 – 10 Hours].These

is used to evaluate all day exposure by a series of continuous samples.

Continuous samples may be thought of as like a motion picture since they

record activity taking place in various places over a period of time. They

provide an average of conditions over a period samples.

B. Other sampling methods

Bulk samples

Bulk samples are collected from settled dust in the work place or from drums or bags

of chemicals. Their purpose is to analyze and identify the substances present. For

example, bulk samples are used to analyze the percent of asbestos in insulation or

dust. Usually, a substance which is greater than one percent of bulk sample is

considered a concern.

Wipe Samples

Wipe samples are used when skin absorption or ingestion is a suspected rote of

exposure. The purpose is to show whether skin, respirators, clothing, lunch rooms,

lockers, etc. are contaminated.

It can show which surfaces are clean and which are contaminated. It can also show

if some surfaces are more contaminated than others.

Sampling Devices

The general principle of sampling is to collect an amount of a contaminant onto a

medium from a known quantity of air.

Air samples are collected using small pumps to suck air from the workroom. The

pump is attached by tubing to a sampling device which contains the sampling

medium; for example a glass tube containing charcoal.

The sampling method used depends on the physical from of the substance:

DUSTS –The sampling device is a filter of plastic or paper in s holder:

VAPORS –The sampling device is a glass tube containing activated charcoal

as a medium.



GASES –The sampling device is a bubbler containing a fluid medium to

dissolved or react with the gas

The collected sample are sent to a laboratory where the amount of the substance on

the sampling medium [filter, tube, etc.] is measured.

In some cases air monitoring is conducted by using direct reading instrument such

as a monitoring for carbon monoxide these instruments can measure the amount of

a contaminant in the air immediately without being sent to a laboratory.

PELs [Permissible Exposure Limits] – these are legal’s limits which have

been established by OSHA.

Recommended PELs – also reference to as RELs [Recommended

Exposure Limits] often these values are based on more recent scientific

information than the legal PELs enforced by OSHA.

TLVs [Threshold Limit Values] – These are exposure limits put out by a

nongovernmental group, the ACGIH [American Conference of

Governmental Industrial Hygienists]. Many of these were adopted as legal

requirements. Revised TLVs are often based on the most recent and

accurate scientific information.

IDLH [Immediate Dangerous to Life or Health] limits are prescribed by

NIOSH [National Institute of Occupational Safety and Health]

AEGL [Acute Exposure Guideline Levels]

SOLVENT / CHEMICAL EXPOSURE LIMITS & EMP FOR THE OCCUPATIONAL SAFETY & HEALTH HAZARDS

TABLE: 7 .5. SOLVENT / CHEMICAL EXPOSURE LIMITS

S. No SOLVENT NAME Exposure Standards

ACGIH [TLV ]

OSHA [ PEL ]

NIOSH [ IDLH ]

1 Methanol 200 200 6000 2 Ethyl acetate 400 400 2000 3 THF 200 200 2000 4 Acetone 500 750 2500 5 Ethanol 1000 1000 3300 6 IPA 400 400 2000 7 Toluene 50 100 500



Notes: All the above Values are in ppm

PPE Means Personal Protective Equipment like Helmets, Safety Google,

Breathing apparatus, Nose Masks, Gloves, Gum Shoes etc.,

NOTE: Medical testing reports of the Employees are enclosed EMP for the Occupational Safety & Health Hazards so that such exposure can be

kept within permissible exposure level (PEL) / Threshold Level value (TLV) so as to

protect health of workers.

1. It is proposed to formulate and implement an EMP for Occupational Safety and

Health with following aim

To keep air-borne concentration of toxic (if available) and hazardous

chemicals below PEL and TLV.

Protect general health of workers likely to be exposed to such chemicals

Providing training, guidelines, resources and facilities to concerned

department for occupational health hazards

Permanent changes to workplace procedures or work location to be done if it

is found necessary on the basis of findings from workplace Monitoring Plan. 2. It is proposed that this EMP be formulated on the guidelines issued by Bureau of

Indian Standards on OH&S Management Systems: IS 18001:2000 Occupational

Health and Safety Management Systems. 3. Proposed EMP will be incorporated in Standard Operating Procedure also

4. The proposed EMP will also include measure to keep air-borne concentration of

toxic and hazardous chemicals below its PEL and TLV, like…

Leak Surveys

Separate storage for toxic chemicals

Exhaust Ventilation

Proper illumination

On-line detectors toxic chemical like Anhydrous Ammonia

Close processes to avoid spills and exposures

Atomization of process operations to hazards of manual handling of chemicals



Supply of proper PPEs like Air mask, Berating canisters, SCBA sets, On-line

breathing apparatus at the places where there is possibility of presence of

toxic chemicals

Decontamination procedure for empty drums and carboys.

Regular maintenance program for pumps, equipment, instruments handling

toxic and corrosive chemicals

Display of warning boards

Training to persons handling toxic and corrosive chemicals .

5. Workplace Monitoring Plan It is proposed that a Workplace Monitoring Plan to be prepared &

implemented in consultation with FMO and industrial hygienists.

Each workplace must be evaluated to identify potential hazards from toxic

substances or harmful physical agents. Air-borne concentration of toxic

chemicals will be measured and record will be kept.

The current state-of-the-art exposure measurement model is as follows: For

purposes of measuring worker exposure across a single shift it is sufficient to

place a reasonably accurate exposure measuring device near the worker’s

area, within the worker’s breathing zone, and have it operate for nearly the full

shift. Client has been proposed to study the exposure data when the plant is

operative.

6. Health Evaluation of Workers It is proposed that management will devise a plan to check and evaluate the

exposure specific health status evaluation of workers.

Workers will be checked for physical fitness with special reference to the

possible health hazards likely to be present, where he/she is being expected

to work before being employed for that purpose. Basic examinations like

1. Liver Function tests,

2. Chest X-ray,

3. Audiometry,

4. Spirometry Vision testing (Far & Near vision, color vision and

Any other ocular defect)

5. ECG, etc. will be carried out.

However, the parameters and frequency of such examination will be decided in

consultation with Factory Medical Officer and Industrial Hygienists.



While in work, all the workers will be periodically examined for the health with

specific reference to the hazards which they are likely to be exposed to during

work. Health evaluation will be carried out considering the bodily functions

likely to be affected during work. The parameters and frequency of such

examination will be decided in consultation with Factory Medical Officer and

Industrial Hygienists. Plan of monthly and yearly report of the health status of

workers with special reference to Occupational Health and Safety, will be

maintained.

7.9. TREATMENT OF WORKERS AFFECTED BY ACCIDENTAL SPILLAGE OF CHEMICALS [Interim First Aid for General Injuries & Wounds]

Interim First Aid is essential in many injuries while injured waits for trained personnel to arrive. BLEEDING

Apply direct pressure on the wound with a clean dressing.

If bleeding continues and you do not suspect a fracture, elevate the wound above the victim’s heart and continue to apply direct pressure.

If bleeding continues, apply pressure at a pressure point.

Maintain body temperature.

Do not use a tourniquet unless this is a serious amputation.

BREATHING PROBLEMS

Move victim to fresh air if smoke or dangerous gases are present.

Otherwise, do not move victim.

If victim loses consciousness, call doctor

Never enter into a room with toxic gases released -call without protection UNCONSCIOUS VICTIM

Move victim to fresh air if smoke or dangerous gases exist.



Begin rescue breathing- is First Aid trained ahead of time! Instead.

Never enter into a room with toxic gases released- call without protection CHEMICAL BURNS

Have victim remain under a safety shower or flush skin with an available water source for 15-30 minutes.

Remove all contaminated clothing and jewellery.

Cover burns with dry, loose dressings.

Wash all clothing thoroughly before wearing it again. ACID BURNS

In case of acid burn, the operator should with all possible speed get under a

safety shower and use the full flow of water - the more water the better. A

small amount of water will incase severity o f the burn Water should be used

until all traces of acid have been washed from the burn. Alkaline solutions are

not needed; if used at all they should be used only after all acid has been

washed from the burn, it may to treat in the same manner as a heat burn.

CHEMICAL INGESTIONS

Never enter into a room with toxic gases released without protection

Do not give victim any food or liquids without specific advice from physician.

EYE INJURIES FROM CHEMICALS

Get victim to a safety shower or eye wash immediately.

Never enter into a room with toxic gases released- call without protection

Flush eye for 15-30 minutes with both lids held open. Keep the injured eye

lower than the uninjured eye.

Keep the eyelids open hold fingers at top and bottom of the eyeball. Wrap a

bandage loosely around both eyes.

7.10. SAFE OPERATING PROCEDURES

Safe operating procedures will be available for mostly all materials,

operations and equipment.



The workers will be informed of consequences of failure to observe the safe

operating procedures.

Safe operating procedures should be formulated and updated, specific to

process & equipment and distributed to concerned plant personnel.

Safety procedures shall be prepared and displayed meticulously in Telugu

and English languages.

7.11. FIRE PROTECTION

Well-designed pressured hydrant system comprising with jockey pump,

electrical & diesel pumps, hydrant, monitor etc. will be installed at the plant.

The fire fighting system and equipment will be tested and maintained as per

relevant standards.

Heat and smoke detectors will be provided at the plant and shall be

calibrated and maintained properly.

7.12. STATIC ELECTRICITY

All equipment and storage tanks/containers of flammable chemicals shall be

bounded and earthed properly.

Electrical pits shall be maintained clean and covered.

Electrical continuity for earthing circuits shall be maintained.

Periodic inspections shall be done for earth pits and record shall be

maintained.

7.13. COMMUNICATION SYSTEM

Communication facilities shall be checked periodically for its proper functioning.

7.14. SAFETY INSPECTIONS

The system shall be initiated for checklist based routine safety inspection and

internal audit of the plant. Safety inspection team shall be formed from various

disciplines and departments.

7.15. PREDICTIVE AND PREVENTIVE MAINTENANCE

Predictive and preventive maintenance schedule shall be followed in religious

manner.



7.16. ELECTRICAL SAFETY

Insulation pad at HT panels shall be replaced at regular interval.

Housekeeping in MCC room shall be kept proper for safe working

conditions.

7.17. COLOUR CODING SYSTEM

Colour coding for piping and utility lines shall be followed in accordance with IS:

2379:1990.

DISASTER MANAGEMENT PLAN

ONSITE EMERGENCY PLAN

OFFSITE EMERGENCY PLAN

7.18. ONSITE EMERGENCY PLAN

The details of Disaster management system are discussed in the following sections

DEFINING THE NATURE / LEVEL OF EMERGENCY

The levels of emergency can be classified in three categories

LEVEL-1

The leakage or emergency, which is confinable the plant, premises. It may be due

to-

Small fire in the plant

Low toxic gas release for short duration.

Collapsing of equipment that do not affect outside premises.

LEVEL-2

The emergency, which is confinable within the factory premises. It may arise due to-

Major fire inside the factory premises.

Medium scale explosion confined to the factory premises.

Heavy toxic/flammable gas leakage for short duration.

LEVEL-3

The emergency, which is not confinable within the factory premises and general

public in the vicinity likely to be affected. It may arise due to-

Explosion of high magnitude affecting the adjacent area

Heavy/profuse leakage of toxic/flammable gases for a long duration.



7.18.1 STRUCTURE OF EMERGENCY MANAGEMENT SYSTEM

The company will develop an emergency management team. The management

structure includes the following personnel

Site main Controllers

Incident Controllers and Deputy Incident Controllers

Key Personnel

Essential Workers

The other elements of Disaster management plan are

Assembly points

Emergency control center

Fire control center

Medical arrangements

Other arrangements

7.18.2 EMERGENCY MANAGEMENT SYSTEM – ROLES & RESPONSIBILITIES

Roles and responsibilities of the responsible persons are described.

SITE MAIN CONTROLLER [SMC]

PLANT HEAD will be the site main controller. In absence of PLANT HEAD, EHS

HEAD will act as a SMC His task will be to co-ordinate all internal and external activities from the emergency

control centre at main security gate from where all operations will be directed. He

shall:

Immediately on being informed of the emergency and its location, will arrive

at the scene and handle the situation.

Relieve the incident controller from responsible of the main controller

Co-ordinate to avail services from external agencies like fire brigade,

hospitals etc. is called for, following the declaration of major emergency. If

necessary, major installations in the vicinity may also be informed of the

situation.

Exercise direct operational control of the unaffected section of the plant.

In consultation with the advisory team, expedite the shutting down of

loading/unloading operations of tankers and if necessary, instruct the

supervisor/security/personnel to evacuate tankers.



Ensure that all employees are evacuated from the affected area and the

casualties, if any, are given necessary medical attention. Instruct P&A

Assistant/security for rushing casualties to hospitals if required.

Liaise with fire and police officials, pollution control board officials and other

statutory bodies and advise them of all possible consequence effects

outside the premises.

Arrange for relief of personnel when emergency is prolonged

Issue authorized statement or press release to the news –media

Ensure preservation of evidence for enquiries to be conducted by statutory

authorities.

Authorize the sounding of “All Clear” and “Evacuation Siren”

Arrange for obtaining the head-count of all personnel within the premises

and cross-checking with the data from records available for no. of persons

within the premise.

INCIDENT CONTROLLER/ DEPUTY INCIDENT CONTROLLER

Role of Incident Controller [Plant Manager/Shift in Charge].He is the shift supervisor

of the plant. Assume the role of the incident controller and take charge of the

situation. Keep the SMC informed of the situation from time to time.

1. Proceed to the scene of emergency and assess the situation

2. Direct all operation within the affected area with the following priorities

Safety of personnel

Minimize damage to property and loss of material

Arrange for rescue of trapped workers and those in a state of shock

Get all non-essential persons safely evacuated after stopping all the

engineering/hot jobs.

Set up a communication system with the main control center at the main

security gate through telephone or messenger system.

Pending arrival of the main controller, direct the shutting down and

evacuation of the site

Report all developments to the main controller

Preserve all evidence for use in the subsequent enquiry.

Intimate to the Emergency Control Center (Main Security Gate) the head

count of plant.



KEY PERSONNEL

Key Personnel are required to provide and to implement the decisions made

by the SMC in the light of information received on the developing situation at

the time of emergency.

As necessary, they will decide the actions needed to shut down plants,

evacuate personnel, carryout emergency engineering work, arrange for

supplies of equipment, utilities, carryout environment monitoring, provide

catering facilities, liaise with police, fire brigade and other local authorities,

relative of casualties, hospital, press & neighboring industries

Action at assembly points, outside shelters and mutual aid center under the

direction of the SMC.

All the key personnel and other called in so to assist shall report to the ECC.

They shall be available at any time on duty or on call or on oil duty or holiday.

ESSENTIAL WORKERS

A task force of essential trained workers [Expert’s team] is available to get the work

done by the Incident controller and the SMC. Such work will include:

Fire fighting and spill control till a FIRE BRIGADE takes the charge

To help FIRE BRIGADE and MUTUAL AID teams, if it is so required

Shuting down plant and making it safe

Emergency engineering work e.g. isolating equipments, material process,

providing temporary by pass lines, safe transfer of materials, urgent repairing

or replacement, electrical work, etc

Provision of emergency power, water, lighting, instruments, equipments,

materials, etc

Movement of equipment, special vehicle and transport to or from the scene of

the accident.

Search, evacuation, rescue and welfare.

The injured is given First Aid.

Moving tankers or other vehicles from area of risk.

Carrying out atmospheric test and pollution control.

Manning of assembly points to record the arrival of evacuated personnel.

Manning for outside shelters and welfare of evacuated persons there.



Assistance at causalities reception areas to record details of causalities.

Assistance at communication centers to handle outgoing and incoming calls

and to act as messengers if necessary.

Manning of works entrances in liaison with the police to direct emergency

vehicles entering the work. To control traffic leaving the works and to turn

away or make alternative safe arrangements for visitors for visitors,

contractors and other traffic arriving at the works.

Informing surrounding factories and the public as directed by the Site Main

Controller.

Any special help required.

7.18.3. OTHER ELEMENTS OF DMP

There are some other elements of DMP which are described as follows:

ASSEMBLY POINT

Assembly points are those locations where the persons who are not connected with

emergency operations can await either for further instructions or for rescue transport

and rehabilitation. Presently outside the plant area is considered as such assembly

points, taking into consideration of the size of the plant facilities. As the location of

security gate is far off the Assembly Point is not vulnerable for emergencies.

In affected & vulnerable plants, all nonessential workers [who are not

assigned any emergency duty] will be evacuated from the area & they shall

report to specified Assembly points.

Assembly Points are located at a safe place, well away from area of risk and

least affected by the down wind direction.

To ensure that workers do not have to approach the affected area to reach

the Assembly point proper location and numbers have been marked at

Assembly points.

Each Assembly Point is manned by a nominated person to record the names

and dept.

At each Assembly point duties of Assembly point, In charge have been also

displayed in brief.

Before reaching an Assembly point or subsequently, if it is required to pass

through an affected area or due to presence of toxic substances, suitable



PPE’s including respirators, helmet etc., are issued & made available with

workers.

EMERGENCY CONTROL CENTER

The emergency Control Center is the place or room from where the operations to

handle the emergency are directed and coordinated. Main Control Room has been

earmarked / identified as the Emergency Control Room. Fire Control Room shall be

earmarked / identified as the alternative Emergency Control Room to be operated in

case of unfavorable wind direction. Adequate Telecommunication System is

available in the Emergency Control Room.

The ECC center has been equipped with the following facilities.

1. Internal and external telephone including STD facility

2. Telephone directory

3. Factory layout plan

4. Map of the area

5. Employee blood group and their address

6. Messengers / Runners for sending messages

7. Adequate numbers of PPE’S

8. Telephone nos. of mutual aid centers

7.18.4. FIRE SERVICES

Fire Fighting, Gas leak Control and Rescue operation

A] Role of Manager (Fire and Safety/shift in-charge [Fire and Safety]

Manager [EHS] shift in-charge [EHS] will be the only person to direct the

fire fighting and emergency operation.

Keep the constant touch with the chief emergency controller.

Direct the crew members to the scene of emergency and arrange

replenishment of man power/equipment/extinguishing media etc.

B] Fire and Safety officer. [EHS Officer]

On being notified about the location of fire/gas leakage immediately

proceed to the scene of incident with fire tender and crew.

Position the fire tender in upwind direction.

Decide his line of action in consultation with incident controller and take

appropriate measures to handle the emergency.



Assessing the severity of the incident immediately report to emergency

controller about the gravity of the situation.

He will assess the extra requirement required if any from the neighboring

industry.

C] Fire Crew Members

On hearing fire alarm, emergency siren they shall immediately report to

control room and proceed to the scene of emergency and work under the

direction of shift fire & safety officer.

The personal availability at the scene of incident to be made optimize.

D] Emergency Squad Members

On hearing Emergency Siren ,they shall immediately report to site main

controller, safety in charge or incident controller

They shall combat the emergency situation as per the direction of site main

controller, Safety In- charge or Incident controller

They shall help for safe evacuation

7.18.5. MEDICAL SERVICES A] Role of Chief Medical Officer/Medical Officer [Medical Assistance]

He will contact immediately to chief emergency controller

He will render necessary treatment as first aid center and hospital.

He will arrange for hospitalization and treatment at outside hospitals if

required.

He will mobilize extra medical assistance from outside if necessary.

He will make arrangement for treating public if necessary.

B] Role of other Medical staff

As directed by medical officers.

7.18.6. SECURITY SERVICES Role of H.O.D. (Security) / Security Officers.

Receive message from the observer

Initiate the emergency siren to declare the emergency

Announce on the public address system



Arrange to close all the gates and stop traffic

Keep vehicle/ambulance ready and keep track of casualty sent to hospital

during off hours

Ensure that unauthorized persons/vehicles do not enter the premises\

Organize the positioning and transport of vehicles near the main gate

Depute security guard for controlling traffic at the scene of emergency

Call up for additional help from the outside agency like fire brigade,

hospitals during off hours

Role of Security Guard

On hearing emergency siren contact security officer and work under his

directions

7.18.7. MUTUAL AID

In emergency situations, resources over and above those available at the works may

be needed. Emergency Coordinator would be contacting neighboring factories for

help. A survey of industries who can come to help and also the help, they can extend

is done as mentioned below.

The help would be in the form of technical manpower, medical aid,

transport for rescue and Rehabilitation, fire fighting, additional special

protective wear or any other help as the case may be.

Manager – Safety who is Emergency Coordinator is assigned with this

responsibility and he would maintain liaison during non-emergency period

and ensure co-operation

Similarly, the help required from civil administration, in respect of medical

aid, transport, law and order, rehabilitation etc. are identified and liaison is

established with Mandal Revenue Officer and Police Officials.

7.18.8. EMERGENCY RESPONSE

Concept of operations deals with the possible steps associated with an

emergency response assuming the most severe emergency scenario. This

includes:

Accident initiation and rising of alarm

Accident evaluation and emergency declaration

Off site and external agency notification



Implementation of onsite response actions

Implementation of protective actions and evacuations

Co-ordination of response action with external agencies

Management of emergency resources

Recovery and facilitate re-entry procedures

7.18.9. EMERGENCY CAPABILITIES

The primary emergency response facilities comprise with emergency control

center upon declaration of emergency, the main security gate office will become

the emergency control center [ECC].The ECC is located in a low /minimal risk

zone of the plant. It is manned round the clock

7.18.10. EMERGENCY HANDLING PROCEDURES

Action plan

On hearing emergency declaration siren and announcement on public

address system, all key persons will rush to their nominated location and

start actions.

The main controller will continuously assess the situation by taking

feedback from the incident controller. He will consult the advisory team

members to get essential information if required but if does not required to

take help from advisory team; he can assign other jobs to advisory team.

Once the emergency is brought under control, Main Controller will inform to

security to give “ALL CLEAR” siren and announce on Public Address

System about termination of emergency.

In the case the emergency assumes off site dimensions and cannot be controlled,

then if the chief controller with his advisory team decides to evacuate the plant, he

will instruct the security to sound “EVACUATION SIREN”

Procedure in case emergency tends to have off site implications

As per the sire plan and wind direction at the time of emergency, the likely

affected area will be identified and population within will estimated.



The police will be informed so that in-coming traffic on highway can be

controlled from both the ends. The police force will be helpful in

evacuation of villages, factories or other public places in the vicinity

The fire brigade will be informed and ambulance will be called and kept

ready to meet any eventuality.

Neighboring factories will be communicated for sending help.

Statutory authorities such as factory inspector, district collector and others

concerned to be intimated.

Procedure for salvage operations

The salvage operation will be carried out under the guidance of the main

controller, his advisory team and incident controller.

They will conduct accident investigation; assess the damages-the clock by

security supervisors.

During emergency, the main controller and his advisory-team will confirm

Master plan of facility and 5kms surrounding area-displayed on wall

Layout of facility, equipment and storages, displayed on table and wall

Availability and location of personal protective equipment

Self-contained breathing apparatus sets and the spare cylinders

External telephone with direct dialing and STD facilities

Internal telephone

List of important internal and external telephone numbers displayed on

table and wall.

Transport facility

Extra copies of plant layout for marking during emergency

Telephone directory both local and surrounding district

General stationary like paper, pencil etc.

Nominal roll and address of all employees with contract telephone no’s

and blood group

List of first aiders and emergency squad members

Details of all contractors and their employees.



Details of meteorological information during different seasons such as

wind speed, direction, temperature, humidity etc.

The location of ECC, Assembly points, availability of first aid boxes, fire

extinguishers, PPE should be marked onsite.

7.18.11. MITIGATION OF ENVIRONMENTAL IMPACT DURING FIRE EMERGENCY

In case of fire, cut of contact of fire with flammable material or prevent

of fire by other means

Use water or suitable fire extinguisher to extinguish fire

Contain the contaminated water or any other liquid to prevent it going to

soil or drain and divert it to ETP storage tank. If required treat it before

sending to ETP tank.

Any solid waste generated should be collected, stored and send to

TSDF site.

During fire emergency use necessary PPE.

Bottom valve failure: mitigation of environment impact during failure of

between valves or tank failure.

In case of material coming out of the bottom valve shall be contained

inside the dyke wall and will be transferred to HDPE plastic drum by

help of pump/piping.

In case of acid spillage after pumping shall be neutralized and waste

shall be cleaned with help of water and send the water to ETP.

The failed bottom valve shall be replaced or repaired and restart. After

tank is empty valve will be repaired, or replaced. In case of leakage

form tank body tank will be repaired.

Preventions of failure: preventive maintenance of bottom value shall be

carried out as per schedule. To prevent any leakage from tank body,

thickness checking shall be same as per schedule.

In case of bottom value failure or heavy leakages from tank body

material in the tank shall be transferred to the HDPE drums, by running

the pump.



Preventions of failure: preventive maintenance of bottom valve shall be

carried out as per schedule. To prevent any leakage from tank body,

thickness checking shall be same as per schedule.

In case of any material leaching the soil it shall be neutralized and

washed with water.

7.18.12. RAISING THE ALARM

Emergency alarm shall be raised in the event of an emergency.

Any person noticing an unusual occurrence, fire, Ammonia leakage, toxic

or corrosive substance leakage etc. shall inform the concerned

department/section head/shift in charge immediately and try to

control/contain the incident.

Departmental head/shift in charge will immediately go to the site of

incident, assess the situation and initiate the action to “blow the

emergency Alarm” by telephoning the main gate to security officer/Asst,

security officer/Security supervisor.

In case of telephone failure a messenger will be sent running to main gate

to inform.

Details of siren are given below

Siren codes

Declaration of emergency:-A long short wailing siren for one minute will

mean that there is an emergency within the premises.

All clear siren: - A long siren for two minutes will mean that the emergency

declared is under control, i.e. all clear. This siren code will mean All clear,

normal condition.

Evacuation siren:-A long short wailing siren for 3 [three] minutes, will

mean that emergency declared cannot be controlled. Hence all persons in

the premises will evacuate as per the plan.

7.18.13. DECLARING MAJOR EMERGENCY

Major emergency may be declared after sufficient thought because it activates many

agencies. The nominated persons to declare major emergencies.



7.18.14. TRANSPORT AND EVACUATION ARRANGEMENTS

Arrangements shall be made for the transport and evacuation of persons in

case of any emergency situation arises in the factory.

Those employees who have own vehicles will make arrangements to shift the

injured.

7.18.15. PLANT OPERATIONS 1. Role of HOD

He will take plant related decisions, which will facilitate the fire fighting

operation.

2. Plant Employees

They shall:

On heaving the siren, report to plant supervisor

Do as directed by plant supervisor

Stop all hot works

Remove unwanted persons from the affected area to the “Assembly Point

“near main security gate viz visitors, guests

Stop all non-essential operations

3. Non-plant Employees

On hearing the siren, shall stop their work assemble at “Assembly Point”

near main security gate along with guests and visitors.

7.18.16 TELEPHONE MESSAGES

Telephone operator has to pay vital role in case of emergency. After hearing the

siren/hooter, he/she should inform to all key personnel immediately on phone.

He/she should receiving be very sharp, precise, attentive and quick in & noticing the

message.

7.18.17 MOCK DRILL

In spite of detailed training, it may be necessary to try out whether, the OSEP works

out and will there be any difficulties in execution of such plan. In order to evaluate

the plan and its effectives of meeting the objective of the OSEP, occasional mock

drills are contemplated. After a few pre- informed mock drills, few un-informed mock

drills would be taken. All this is to famiarize the employees with the concept and



procedures and to see their response. These scheduled and unscheduled mock

drills would be conducted during shift change, public holidays, in night shifts etc, to

improve preparedness. Emergency Coordinator [EHS] is responsible for organizing

planned and unplanned mock drills.

Two types of Mock drills are in practice. They are

1. Announced-Once in 3 months

2. Unannounced –Once in 6 months.

Mock drill observation

Mock drill observation team [ERT members] is constituted and they note down the

action of various coordinators in chronological order. The time of arrival of each

coordinator and their duties are detailed in a note. Immediately after mock drill, the

advisory team and emergency coordinators meet and review the mock drill records

in chronological order and take note of corrective action. The record of this meeting

note is circulated for compliance of concerned.

Role of Mock drill observers

Note readings of plant instruments

Meteorological conditions

Time of emergency declaration and time when the personnel responded /

reported

Ambulance reported and time when additional vehicles reported

Collect information description of the event, estimated quantity of the gas

release, fire, contamination and effected levels at various locations, injuries

and equipment damage.



7.19. OFFSITE EMERGENCY PLAN “If the accident is such that its affects inside the factory are uncontrollable and it may spread outside the factory premise, it is called “as OFFSITE EMERGENCY

FLOWCHART FOR OFFSITE EMERGENCYPLAN

The Offsite emergency plan is made based on events, which could affect people and

Environment outside the premises. The off site plan is largely a matter of ensuring

the co-ordination of proposed services and their readiness as far as possible, for the

specific hazards and problems, which may arise in as incident. Briefly two main

purposes of the plan are as under:

To provide the local district authorities, police, fire brigade, doctors etc. the basic

Information of risk and environmental impact assessment and to appraise them of

the consequences and the protection / prevention measures and control plans and to

seek their help to communicate with the public in case of major emergency. To assist

the district authorities for preparing the offsite emergency plan for the district or

particular area. We have made our key personnel and other fully aware about this

aspect. The function of the offsite plans are as under:



Structure of the offsite emergency plan includes the following:-

Organizational set up-Incident controller /Site main controller, Key personnel,

etc

Communication facilities - List of important telephones

Specialized emergency equipment - Firefighting equipment

Specialized Knowledge - Trained people

Voluntary Organization - Details of organization

Chemical information - MSDS of hazardous substances

Meteorological information - Weather condition, Wind velocity etc

Humanitarian arrangement - Transport, First aid, Ambulance

ROLE OF THE FACTORY MANAGEMENT

The onsite and offsite plans are come together so that the emergency services are

call upon at the appropriate time and are provided with accurate information and a

correct assessment of situation.

ROLE OF LOCAL AUTHORITY

Generally the duty to prepare the off-site plan lies with the local authority. They may

have appointed an emergency planning officer (EPO) to prepare whole range of

different emergency within the local authority area.

ROLE OF FIRE AUTHORITY

The control of a fire is normally the responsibility of the senior fire brigade officer who

would take over the handling of fire from the Incident Controller on arrival at the site.

ROLE OF POLICE

The overall control of an emergency is normally assumed by the police with a senior

officer designated as emergency coordinating officer. Formal duties of the police

during emergency include protection of life and property and controlling traffic

movements.

ROLE OF HEALTH AUTHORITIES

Health authorities, including doctors, surgeons, hospitals, ambulances etc. have a

vital role to play following a major accident and they should form an integral part of

the emergency plan. Major off site incidents are likely to require medical equipments

and facilities in addition to those available locally.



ROLE OF THE “MUTUAL AID” AGENCIES

Some types of mutual aids are available from the surrounding factories, as per need,

as a part of the onsite and offsite emergency plan.

THE ROLE OF THE FACTORY INSPECTORATE

In the event of an accident, the factory inspector will assist the District Emergency

Authority for information and help in getting mutual aid from surrounding factories.

Unit maintains the records of details of emergency occur, corrective preventive

measures taken and in future the same practice will be continued. Unit has displayed

the details like list of assembly points, name of the persons involve in the safety

team like site controller, incident controller etc.

PROJECT BENEFITS

CHAPTER -VIII


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter - VIII Page 1

CHAPTER – VIII PROJECT BENEFITS

The proposed project will become beneficial to the surrounding area or community in

terms of employment, social development and other benefits as described hereunder;

8.1 EMPLOYMENT OPPORTUNITY In the proposed unit 50 persons are employed for the various job categories. For the

project persons are expected to employ for the skilled, semi-skilled and unskilled

category. The preference will be given to local population for employment

in the semi-skilled and unskilled category; this will increase the employment opportunity

in the surrounding area. The ideology of the company is to give employment opportunity

to nearby villagers and this is the most positive aspect of company regarding

enhancement of the society. Secondary jobs and indirect employment are also bound to

be generated to provide day-to-day needs and services to the work force and industrial

activity. This will also increase the demand for essential daily utilities in the local market.

Due to proposed project there will be development of communication facilities in the

area. The employed people will be benefited financially. This financial gain will fulfill

their monetary requirements, which in turn will increase their standard of living.

8.2 CORPORATE SOCIAL RESPONSIBILITY (CSR) & SOCIO-ECONOMIC DEVELOPMENT

Vensar Laboratories Pvt. Ltd not only carries out business but also understands the

obligations towards the society. The unit is aware of the obligations towards the society

and to fulfill the social obligations unit will employ semi-skilled and skilled labor from the

nearby villages for the proposed project as far as possible. Unit will also try to generate

maximum indirect employment in the nearby villages by appointing local contractors

during construction phase as well as during operation phase.

Unit will be contributed reasonably as part of their CSR and carried out various activities

in nearby villages. The various CSR activities identified and planned at present are

described below Table.



CSR ACTIVITIES PLANNING & BUDGET FROM

VENSAR LABORATORIES PVT. LTD.

PROJECT LOCATION Survey No: 32, Tupakulagudem (V) Tallapudi (M),

West Godavari (Dist.), Andhra Pradesh.

CSR PLAN PERIOD Five Years Activity Plan from the date of commercial production

CSR Activities

PROJECT AREA DETAILS

AREAS COVERED .

CSR Work Plan & Budget Highlights

Note: Project cost: Rs. 6.00 Crores

CSR Budget allocation is Rs. 30 Lakhs [5% of the Project cost] for 60 months [5 Years]



S.NO

FOCUS AREA

1ST YEAR

2ND YEAR

3RD YEAR

4TH YEAR

5TH YEAR

GRAND TOTAL

FOR 60 MONTHS

(IN LAKHS)

PROPOSED ACTION PLAN

1 Water Sanitation 2 2 2 2 2 10

Provision of safe drinking water during water crises circumstances. Build water storage structures with the coordination of government. Provision of sanitation facility in the villages by building common toilets

2 Education 1.5 1.5 1.5 1.5 1.5 7.5

Organizing Camps to create awareness and need of necessary education to all children’s including dropouts.

Adopting one primary school of the vicinity and we supply necessary infrastructure such as benches, dusks, black boards and also provide books and other writing materials.

Proposed to have more focus on girls education and to reduce the dropouts to the extent possible by creating awareness in their parents

3 Self Help Skill Training 1 1 1 1 1 5

Based on local identified needs, we will set up training centre to impart skills such as tailoring, toys making, book binding and basic computer skills to local women and men

Self help skill Training : Unskilled /Semiskilled persons will be identified in villages and given necessary training as per industry requirement and we will absorb the personnel in industry as and when need arises

4 Environment 1 1 1 1 1 5

This would be the main focus area whereby beneficial saplings will be distributed to the Villagers & elaborate awareness programme will be conducted on how to maintain clean & green environment and to protect water bodies

Identifying water collection points during the rainy season to construct Rain Harvesting pits there by water resources shall be conserved more efficiently.

5 Other Social

Welfare Activities

0.5 0.5 0.5 0.5 0.5 2.5

Financial & infrastructure assistance during disaster & other crisis incidents Participate & contribute in local religious and social programs Plantation along the road side and development of garden / greenbelt on government barren land / common plots.

Total CSR Budget 6 6 6 6 6 30.0



A. Water and Sanitation 1. Provision of safe drinking water during water crises circumstances.

2. Build water storage structures with the coordination of government.

3. Provision of sanitation facility in the villages by building common toilets

B. Education 1. Award Scholarships/fellowships to deserving students to encourage education.

2. Provision of uniforms, books, and stationery, necessary equipments etc, to schools.

3. Promote Technical/ professional/ medical education by giving financial assistance.

4. Promote computer literacy and technology assisted learning.

5. Reducing the drop out of students & absenteeism through counseling & other means.

6. Organize skill development program for sustainable income generation & livelihood

for the community like training on scientific agricultural practices, tailoring, embroidery,

etc.

7. Vocational training for Youth & Women.

8. Conducting awareness programs to reduce child labor in the villages

9. Promotion of adult education with focus on women’s education.

C. Self Help Skill Training 1. Based on local identified needs, we will set up training centre to impart skills such as

tailoring, toys making, book binding and basic computer skills to local women and men.

2. Self help skill Training: Unskilled /Semiskilled persons will be identified in villages and

given necessary training as per industry requirement and we will absorb the personnel

in industry as and when need arises.

D. Environment

1. This would be the main focus area whereby beneficial saplings will be distributed to

the Villagers & elaborate awareness programme will be conducted on how to maintain

clean & green environment and to protect water bodies

2. Identifying water collection points during the rainy season to construct Rain

Harvesting pits there by water resources shall be conserved more efficiently.



E. Other Social Welfare Activities

Financial & infrastructure assistance during disaster & other crisis incidents

Participate & contribute in local religious and social programs

Plantation along the road side and development of garden / greenbelt on

government barren land / common plots.

8.3 DIRECT REVENUE EARNING TO THE NATIONAL AND STATE EXCHEQUER This project will contribute additional revenue to the Central & State exchequer in the

form of excise duty, income tax, state sales tax or VAT, tax for interstate movement,

corporate taxes etc. Indirect contribution to the Central & State exchequer will be there

due to Income by way of registration of trucks, payment of road tax, income tax from

individual as well as taxes from associated units. Thus, the proposed project will help

the Government by paying different taxes from time to time, which is a part of revenue

and thus, will help in developing the area. Demand of the proposed products in foreign

market is also significant, which will boost the export potential of the company as well as

country. Export oriented units plays vital role in development of economy as well as

local physical infrastructure for further boosting of industrial development with

sustainable approach as the industries need to maintain good environment & safety

condition to get better foreign market.

8.4 INFRASTRUCTURAL BENEFIT The project site is equipped with sufficient infrastructural facilities including drinking

water, toilets, sanitation facilities, power, easily accessible approach roads, public

transport, communication, etc. Hence no major benefit to the public infrastructure is

anticipated due to the proposed project. However, benefits due to CSR activities may be

realized if any CSR activities would be related with such facilities.

8.5 OTHER TANGIBLE BENEFITS The proposed project will have many employment & trade opportunities with the

inception of the construction activities. Thus, these considerable employment & trade

opportunities will eventually result in appreciable economic benefits to the local people

& businesses/contractors. The country shall also benefit from increase in excise and vat

revenues. Foreign exchange earnings from exports are envisaged to increase. Beside

of the economic benefits, the general social & cultural development of the area is



anticipated at least due to the CSR activities planned by the company. The CSR

activities to be planned by the company can be considerably beneficial for Education,

Self Help Skill Training & Environment, assistance to the disabled people etc. These all

together with the economic benefits of the proposed project will result in further benefits

in terms of the literacy level, primary and middle level education and on health facilities.

A new awareness generated can also have benefits to the social pattern. The long-term

implications of this change can be definitely considered as progressive.

ENVIRONMENT COST BENEFIT ANALYSIS

CHAPTER -IX


Prepared By Rightsource Industrial Solutions Pvt. Ltd Chapter – IX Page 1

CHAPTER - IX

ENVIRONMENT COST BENEFIT ANALYSIS

9.0 COST BENEFIT ANALYSIS

During the scoping stage; no recommendation of environmental cost benefit analysis is suggested by the appraisal committee.

ENVIRONMENT MANAGEMENT PLAN

CHAPTER -X


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter – X Page 1

CHAPTER – X ENVIRONMENTAL MANAGEMENT PLAN

10.1 INTRODUCTION

Environmental Management Plan reflects the commitment of the management to

protect the environment within and outside the industrial premises. An environmental

management plan is required for formulation and monitoring of environmental

protection measures during and after construction and commissioning of the

projects. Hence, the construction and operational phase is considered for outlining

the Environmental Management Plan for the said industry. The plan indicates the

details as to how various measures have been taken by the industry to mitigate the

pollutants generated due to its operations.

The Potential Environmental Impacts from the construction and operational activities

of the industry are summarized below.

A. Construction Phase:

Site preparation, sanitation, noise, construction equipment & waste and site

security.

B. Operation Phase:

Air pollution due to emission of Particulate Matter, Sulphur dioxide, Nitrogen oxide from the boiler stack and D.G. Set.

Gaseous emissions from process leading to workroom air pollution.

Noise pollution due to noise generating equipment operation.

Disposal of effluent generated due to plant operations.

Disposal of Solid Wastes generated due to the plant operation.



FIGURE -10.1: FLOW CHART OF EMP

IDENTIFICATION OF THE

POTENTIAL IMPACTS

RECOMMENDED MITIGATION

MEASURES

DESCRIPTION OF MONITORING PROGRAM

ENSURE COMPLIANCE WITH RELEVANT STANDARDS AND RESIDUAL IMPACTS

ALLOCATION OF RESOURCES AND RESPONSIBLITIES FOR

PLAN IMPLEMENTATION

IMPLEMENTATION SCHEDULE AND REPORTING

PROCEDURES

CONTIGENCY PLAN WHEN IMPACTS ARE GREATER THAN

EXPECTED



10.2 PRE- PROJECT ENVIRONMENTAL MANAGEMENT PLAN

Construction related impacts:

Vensar Laboratories Pvt. Ltd is a new project. The potential for environment pollution

during the construction is obviously considerably less than when the plant is in

operation. The following factors require control during the construction phase.

10.2.1 Site Preparation

The leveling operation will involve stockpiling of backfill materials. All the disturbed

slopes shall be stabilized with grass cover and dust nuisance controlled.

10.2.2 Sanitation

The site should be provided with sufficient and suitable toilet facilities with proper

hygiene for construction workers. Adequate potable water supply shall be provided

for onsite workers.

10.2.3 Noise

The total noise effect in the vicinity during construction stage will be negligible in the

site and the site is far away from the nearest human habitation.

10.2.4 Construction Equipment and Waste

It should be ensured that construction related vehicles are properly maintained to

minimize exhaust emissions. Combustible waste should be burnt in a controlled

manner. Other wastes shall be disposed off in approved dump yard. Spent liquid

waste if any, arising from chemical treatment of built-up portions for termites etc,

shall be neutralized and disposed off.

10.2.5 Site Security

The site shall be secured by fencing and manned at entry points.



10.3. ENVIRONMENTAL MANAGEMENT DURING OPERATION 10.3.1 AIR QUALITY

The process emissions, boiler emissions and emissions from D.G. Sets are the

sources likely to contribute to air pollution. Solvent emissions will also contribute to

the air pollution marginally. Adequate measures are being taken to minimize the

impacts of these emissions on the environment.

The baseline data collected during the study period indicate that all seven pollutants

namely PM2.5, PM10, SO2, NOX, CO, NH3 and VOCs, is well within the limits

prescribed by CPCB.



local authorized sources, and the company is proposing 2, 00,000 K. Cal / Hr.

Thermo pack Agro Waste fired / Coal fired Boiler. Proposing a 250 KVA DG set for

usage during the power failures.

There will be slight increase in the ground level concentrations for PM2.5, PM10, SO2,

NOX, CO, NH3 and VOCs.

10.3.1.1 AIR POLLUTION CONTROL / MANAGEMENT

Following are the proposed pollution control schemes and which will be used to

minimize, and control the emission of air pollutants as well as their effective

dispersion into the atmosphere.

A. Stack Design

The boiler stack height of 32 meters will be provided along with SPM controlling

equipment cyclone separator followed by Bag Filter. The approximate flue gas

velocity of 8.5 m/s from stack ensures proper dispersion of the flue gas into

atmosphere. The design will ensure the ground level concentration of the pollutants

to comply with the ambient air quality standards.

B. Air Environment - Process Emission Control

Process emissions are which is liberated from manufacturing process of

proposed products.



Expected Air Environment (Expected Process Emissions Details):

Process emissions are HCl, HBr, CO2, H2 and O2 which is liberated from

manufacturing process of proposed products.

EXPECTED PROCESS EMISSION DETAILS

S. No Name of the Gas Quantity In Kg/Day Disposal Method







C. ACTION PLAN TO CONTROL AMBIENT AIR QUALITY AS PER NAAQS STANDARDS

S.NO POLLUTANTS

STANDARDS (Industrial, Residential,

Rural and Other Area)

CONTROL MEASURES RESULT

Process Boiler DG Sets

1 Sulphur Dioxide (SO2) µg/m3

50

80 N.A

Providing 32 m of stack height to Dispersed into

Atmosphere

Providing 10m of stack height to Dispersed into

Atmosphere Within the Limit

2 Oxides of Nitrogen as NO2 µg/m3

40

80 N.A


Atmosphere



3 Particulate matter (size Less than 2.5µm) µg/m3

60

100 NA Providing Cyclone separator

followed by bag filter NA Within the Limit

4 Particulate matter (size Less than 10µm) µg/m3

40

60 NA Providing Cyclone separator

followed by bag filter NA Within the Limit

5 Ozone µg/m3

100

180 NA NA NA -

6 Lead (Pb) µg/m3

0.50

1.0 NA NA NA -

7 Carbon Monoxide (CO)

02

04 NA


Atmosphere



8 Ammonia (NH3) µg/m3

100

400 NA NA NA Within the Limit

9 Benzene µg/m3 05 NA NA NA -

10 Benzo(a) pyrene (BaP)- Particulate Phase only ng/m3

01 NA NA NA -

11 Arsenic ng/m3 06 NA NA NA - 12 Nickel ng/m3 20 NA NA NA -



D. Fugitive Emissions from Solvents

Various types of solvents are used in the Bulk Drug manufacturing process. The

solvents will be stored in drums and Bulk quantities in storage tanks with vent

condensers. These are handles in closed conditions thereby reducing the losses in

the form of evaporation. The industry will take measures for reduction of fugitive

emissions by providing Chilled brine circulation to the condensers, which ensures the

recovery of 95% and also controlled by closed operations and handling methods.

Good ventilation will be provided to reduce the workroom concentrations. The

chemical reactions in reactor generating solvent vapors will be controlled by

connecting vents to condensers with receivers.

E. Storage and Transportation of Raw Materials Raw materials will be received by trucks and tankers. The same will be stored in

storage rooms; it is stored under lock and key in designated storage area. The

chemicals will be received in Fiber drums, HDPE drums, and PP bags.

F. Storage and Transportation of Solvents Solvents like Acetone, Ethanol etc will be received in road tankers. The same will be

stored in storage tanks. Dyke will be constructed around the tankers with leachate

collection system. The tanks will be provided condensers with reflex to prevent

fugitive emissions and flame proof arrestors. The solvents will be transferred to

production blocks through pipelines.

The solvents like Methanol and others with transforming pumps [low solution] will be

received in drums (MS\HDPE). Such solvents will be stored under shade and

consume as early as possible. The same will be stored on an elevated platform

provided with Concrete floor and leachate collection pits. The solvents will be

transported to production block by means of drum trolley.

All containers or tanks containing waste destined for transportation shall be labeled

with the type of solvent, waste and its hazards. The packing shall be secure enough

to prevent leaks, spills and vaporization during transport. All the storage tanks and

drums storage area will be built as per the norms of the PESO (Petroleum Explosive

Safety Organization.)



10.3.2 NOISE POLLUTION

All the equipment in the plant would be designed to have a total noise level not

exceeding 85-90 dB (A) as per the standards.

NOISE ENVIRONMENT

Compressors, Boiler and DG set will be the major noise generating units in the plant.

Out of these the generator will be functioning only at the time of power failure. There

is no need for the workers to be near this unit continuously. Apart from this the

Generator sets are placed in separate rooms with an acoustic enclosure as

permitted by CPCB.

NOISE POLLUTION CONTROL / MANAGEMENT

The noise levels in the work place environment will be monitored periodically

and if necessary action will be taken in the form of regular maintenance

schedule to reduce noise and vibration in generating sources.

The effects of the vibrations coming out of the base of the body over the

surrounding civil structures are minimized by providing Damping

pads/Resilient mounting at the time of installation.

Under the general health check up scheme as per factory act, the workers will

however be checked up for any Noise induced Hearing Loss (NIHL) by a

trained ENT Doctor.

10.3.3 WATER QUALITY No impact on water quality is due to no discharge of effluents. Water is essentially

used in Process, Boilers, cooling towers and for domestic purpose. The total water

required for the plant is drawn from bore wells within the plant premises.

WATER POLLUTION CONTROL / MANAGEMENT

The effluent generation is from process, boiler blow down, DM Plant Regeneration,

Scrubbing system, Floor & Reactor washings and Domestic sections.

Water shall be recycled to reduce the impact on water resource and the

industry will implement the Zero Discharge of Waste water by opting ZLD

treatment system to recycle and reuse the water for plant utilities.



Process effluent will be segregated based on COD & TDS concentration and

collected separately by gravity from all sources into a collection Pit.

Collected waste water from different sources will be pumped in to the above

ground level tanks separately.

The unit will provide Wastewater Treatment Plant (ETP) to treat the trade

effluent

Treatment system

The effluent will be neutralized, the HTDS/HCOD effluent will be sent to steam

stripping Column for collection of solvents/Organics which are dissolved in the

waste water stream. After stripping effluent will be sent to Multiple Forced

Evaporation system which contains 3 Calandrias. Stripped organics collected

and sent to cement industry/TSDF incinerator.

The concentrate from the MEE System will be sent to ATFD and salts from

the ATFD will be collected and sent to TSDF for safe disposal.

The condensate from MEE followed by ATFD sent to biological system for

Treatment.

The LTDS effluent along with MEE / ATFD condensate will be sent to

Biological treatment, treated effluent sent to RO for water recovery.

The RO permeate will be reused and RO reject will be sent to MEE for further

evaporation.

All the treatment tanks etc. is constructed / installed only with acid proofing

and 1.5 to 2.5 meters above the Ground Level.

Roof Water Harvesting System will be put in practice to recharge the ground

water and to use the same for various requirements and to reduce the ground

water extraction.

Strategic control / Management

Minimizing of water use.

Segregation and collection philosophy for effluent to minimize waste

generation and facilitate treatment as well as recycle and reuse.

Reducing the actual process water consumption by way of improvement in operation of processing units.



FIGURE -10.2: SCHEMATIC DIAGRAM OF WASTE WATER TREATMENT

TOTAL EFFLUENT WATER

40.00 KLD

LTDS 15.60 KLD

DOMESTIC 2.40 KLD

HTDS 22.00 KLD

RO = 45.00 KLD 15.60+19.8=35.4

MEE = 45.00 KLD 22.00+14.16=36.16

SOAK PIT

40% REJECT 14.16 KLD 90%

CONDENSATE

60% PERMEATE 21.24 KLD

REUSE

ATFD

TSDF

BIOLOGICAL TREATMENT



FIGURE-10.3: FLOW CHART FOR EFFLUENT TREATMENT HTDS & HCOD



FIGURE-10.4: FLOW CHART FOR EFFLUENT TREATMENT LTDS



10.3.3.1 DETAILS OF ZLD SYSTEM

All the effluent generated from the plant are collected in the Effluent collection pits

and from those pits effluent will be pumped to the above ground storage tanks

through the closed HDPE pipe lines. All these effluent collection pits are lined with

acid proof tiling or HDPE lining.

The Industry will construct the above ground storage tanks to store the collected

effluent from various streams. The tanks consist of 6 Compartments and are used to

store the HTDS and LTDS effluents separately. These tanks can accumulate the 4

days generation.

The HTDS effluent consists of COD will be sent to the Stripping Column and the

COD will be removed here after the removal of COD from the effluent it will be sent

to the MEE system which consists of 3 Calandrias and the condensate will be

collected. After this the balance will be sent to ATFD and the balance condensate

will be collected. We can achieve 90% of the water recovery by this process. The

solid waste generated from the ATFD will be stored securely and will be transported

to TSDF for secure Land Fill.

Now, the Condensate water from the MEE system along with the LTDS effluent will

be sent to the ETP system for the removal of balance COD etc., The ETP system

consists of Aeration and Clarification. After this the effluent is passed through the

Sand Filter, Carbon Filter and Micron Filters and finally through the RO System.60%

of the effluent comes out as RO permeate and will be reused in the plant operations.

Remaining 40% of the water will be sent to MEE system for Evaporation.

FIGURE-5: FLOW CHART FOR EFFLUENT TREATMENT

Effluent Type Treatment Flow

HTDS

Collection Equalization & neutralization Stripper MEE ATFD TSDF MEE/ATFD Condensate sent to Biological Treatment followed by RO.

LTDS Collection ETP (Biological Treatment) Sand Filter Carbon Filter Cartridge Filter RO Plant RO Reject to MEE. RO Permeate for Reusage.



10.3.3.2 The Technical Details of the Systems are as follows:

MEE System Capacity: 45.00 KLD

RO System Capacity: 45.00 KLD

10.3.3.3 MEE Plant Configuration

Part – A: Stripper Unit with Flash Condenser, Re boiler and Recirculation Pump

Part–B: Triple Effect Forced Circulation Evaporation Plant with Thermo Compressor,

Required Equipment & Components.

Part – C: Agitated Thin Film Dryer

10.3.3.4 PROCESS DESCRIPTION (Part – A)

1. Feed will enter to the series of Pre heaters of Evaporator P4, P3, P2 and then

P1 using Feed Pump. From Discharge of Feed Pump Feed will be heated

through Series of Pre heater using Vapour from Jacket of respective

Calandria. Feed will be heated to the boiling point and will enter to the

recirculation loop of Stripper.

2. Recirculation Loop of Stripper will comprise of Flash Vessel, Recirculation

Pump and Re boiler.

3. Feed coming out from Pre heater of Evaporation Plant will recirculate through

re boiler and heated up using Steam.

4. Heated Feed will allow flashing in Flash Vessel and by flashing high volatiles

and Water will convert to vapour. Vapour will travel from bottom to top of

Stripping column where feed liquid will flow from top to bottom. Random

packing inside the stripping column provide mass transfer surface to vapor

liquid interface.

5. Rich organic vapour with some water vapour will come out from the top of

Stripper column. This vapour will be condensed in Flash Condenser at the top

of Stripper column.

6. Condensed organic rich liquid will be collected in Reflux pot from condenser.

From Reflux pot partly it will be withdraw according to the desired Water

Vapour/ Organic ratio and remaining will enter to the column as reflux.



10.3.3.5 PROCESS DESCRIPTION (Part - B)

1. From Discharge of Stripper recirculation Pump feed will enter to the

Evaporation Plant. Feed will enter to the Evaporation Plant from Discharge of

recirculation pump of Stripper.

2. First Effect is a Forced Circulation Type comprising of Calandria-1, Vapour

Separator-1 and Recirculation Pump– 1. Liquid will recirculate continuously a

through Calandria Tubes at high velocity and will get heated using Heat of

Condensation of First Effect Jacket. This Heated Mass will allow to flash in

Vapour Separator and Water Vapour being generated.

3. This Flash Vapour will partly recompressed to the Jacket of First Effect using

Thermo compressor which will convert high pressure motive steam to low

pressure and will create suction and take part of the water vapour from

Vapour Separator -1.

4. Condensate from Jacket of First Effect will travel to 2nd Effect using pressure

difference available between these two Jackets.

5. Concentrate will be coming out from 1stEffect will be sent to Balance Tank -2

which will be placed between 1stand 2ndEffect.

6. Second Effect also is a Forced Circulation Type comprising of Calandria-2,

Vapour Separator-2 and Recirculation Pump– 2. Liquid will recirculate

continuously a through Calandria Tubes at high velocity and will get heated

using Heat of Condensation of Second Effect Jacket. This Heated Mass will

allow to flash in Vapour Separator and Water Vapour being generated.

7. Flash Vapour will come out from Vapour Separator -2 and will be utilize as

heating media for 3rd Effect.

8. Condensate from Jacket of 2nd Effect will travel to 3rd Effect using pressure

difference available between these two Jackets.

9. Concentrate coming out from 2nd Effect will be below saturation level and

there will not be any crystallization takes place in 2nd effect.

10. Feed will enter to the Recirculation Loop of 3rd Effect which is forced

Circulation Type comprising of Calandria-3, Vapour Separator-3 and

Recirculation Pump – 3. Liquid will recirculate continuously a through

Calandria Tubes at high velocity and will get heated using Heat of



Condensation of Third Effect Jacket. This Heated Mass will allow to flash in

Vapour Separator and Water Vapour being generated.

11. Condensate coming out from 3rd Effect Jacket is a mixture of Steam utilized in

Thermo compressor and Evaporated Water Vapour from 1st and 2nd effect.

Condensate will be taken out from plant using Condensate Outlet Pump and

send for Storage.

12. Concentrate from Evaporation will be taken out from the Plant using

Concentrate Outlet Pump and send to ATFD.

13. Water Vapour from Last Effect will be condensed in surface type condenser

using Cooling Water as condensing media. Steam Jet Ejectors/ Water ring

Vacuum Pump will maintain vacuum in the plant back to the condenser.

10.3.3.6 PROCESS DESCRIPTION (Part - C)

1. Feed Pump will be gear/ roto type pump to handle viscous Feed. Feed will not

required to preheat as it will come at 85-90 Deg C from the tank. Feed will

enter to the Vertical ATFD first for initial evaporation. Feed will splash to the

Heat Transfer Surface of ATFD using liquid distributor.

2. V-ATFD will be a hollow cylindrical Jacketed Vessel having Agitator and

specially designed Scrapper blades to wipe out the Surface of ATFD all the

time to keep it clean. This will maintain consistent performance of ATFD for a

long time.

3. ATFD Scrapper will rotate at medium RPM using Gear Box for reduction of

RPM which will be govern by Variable Frequency Drive.

4. ATFD Heat Transfer Surface will be heated through Steam in Jacket. Vapour

outlet will be connected with Entrainment Separator to avoid product

contamination in Condensate. Vapour will be condensed in Condenser and

Negative draft will be maintained by Water Ring Vacuum Pump.

5. Product coming out from bottom of Vertical ATFD. Steam will be applied in

Jacket of same to allow the product dry.



10.3.3.7 MATERIAL OF CONSTRUCTION

S. No Particulars M.O.C Stripper Unit

1

Flash Stripper column Main Shell SS 304 Packing material SS 316 - IMTP Baffles SS 316 Flash Vessel SS 316

2

Flash condenser Main Shell SS 304 End Cover SS 304 Tube Sheet SS 304 Tubes SA 249 TP 304

3

Re-Boiler Main shell Carbon Steel End Covers SS 316 Tube sheet SS 316 Tubes SA 213 TP 316

4 Recirculation Pump SS 316 5 Reflux Pot Carbon Steel

Evaporator 6 Calandria

Main Shell SS 316 Top Cover SS 316 Bottom Cover SS 316 Tube Sheet SS 316

Tubes SA 213 TP 316 Seamless

7 Preheater Main Shell SS 316 Top Cover SS 316 Bottom Cover SS 316 Tube Sheet SS 316

Tubes SA 213 TP 316 Seamless

8 Pumps Feed Pump SS 316 Recirculation Pumps SS 316 Concentrate outlet Pump SS 316 Condensate/Hot Water SS 304

9 Vapour Separators SS 316 10 Vapour Ducts SS 304 welded 11 Thermo compressor SS 304 12 Process Pipes & Fittings SS 316 13 Condensate & Non-Condensable Pipes &

Fittings SS 304



14 Primary condenser/ Secondary Condenser Main Shell SS 304 End Cover SS 304 Tube Sheet SS 304 Tubes SA 249 TP 304

15 Steam Jet Ejector SS 304 16 Balance Tank MSRL

Agitated Thin Film Dryer 17 Inner Shell SS 316 18 Jacket Shell Carbon Steel 19 Rotor/ Scrapper SS 316 20 Shaft EN 8 21 Surface Condenser Carbon Steel 22 Steam Jet Ejector SS 304 23 Entrainment Separator SS 316 24 Salt Collection Tank SS 316 25 Condensate Collection Tank Carbon Steel

10.3.3.8 DETAILS OF 45 KLD MEE SYSTEM

S. No Description Unit Unit 1 Feed Quantity Lit/hr 2250

Lit/day 45000 2 Feed Temperature Deg C Ambient 3 Operating Hours Hr. 20 4 Initial Concentration % 3 5 Steam Pressure Kg/Cm2 5.0 6 Cooling Tower Temperature Deg C 32

Part – A: Stripper Unit

S. No Particulars Unit Value 14. Feed to the Stripper Column Kg/hr 2250 15. Total Solids in concentration % 7.0 16. Stripper Top Estimated Kg/hr 225 17. Final Output Kg/hr 2025 18. Motive steam pressure Kg/cm2 5.0 19. Motive steam quantity required Kg/hr 125 20. Cooling water inlet temperature o C 32 21. Cooling water outlet temperature o C 38

22. Cooling water recirculation quantity in flash condenser m3/hr 21

23. Power Consumption Stripper

KW 4.3



Part – B: Triple Effect Forced Circulation Evaporation Plant

S. No Description Unit Value 24. Feed rate Kg/hr. 2025 25. Evaporation Capacity Kg/hr 1620 26. Initial Solid Concentration % 7.78 27. Concentrate Outlet (40%) kg/hr 390 28. Motive Steam Pressure Kg/cm2 5.0 29. Motive Steam Consumption Kg/hr 225 30. Cooling Water Inlet Temperature 0C 32 31. Cooling Water Outlet Temperature 0C 38

32. Cooling Water Quantity M3/hr 42 33. Power Consumption (Evaporator) KW 24.00

Part – C: Agitated Thin Film Dryer

S. No Description Unit Value 34. Feed Rate Kg/hr 390 35. Evaporation Capacity Kg/hr 98 36. Initial Solid Concentration % 40 37. Concentrate Outlet(With 8-10% Moisture) Kg/hr 78 38. Motive Steam Pressure Kg/cm2 5.0 39. Motive Steam Consumption Kg/hr 138 40. Cooling Water In/ Out Temperature Deg. C 32/38 41. Cooling Water Quantity M3/hr 22 42. Power Consumption KW 16 43. Heat Transfer Area M2 7.5



FIGURE-10.6: SCHEMATIC DIAGRAM OF MEE SYSTEM



10.3.3.9 ETP WITH RO PLANT CONFIGURATION

Low TDS ETP system is designed for basic drug industry and used for waste water

having TDS of about 5000 ppm. However can be used for a max TDS of 6000 ppm.

Low TDS ETP storage tank: Low TDS effluent water is to be stored in a neat tank

so as to reduce contamination from other sources.

Aeration system: The system consists of a twin lobe blower – roots blower one

working and one stand by for aeration having a header pipe with diffusers and RCC

bricks with suitable flexible pipes between diffusers and header pipe. Aeration

system is most important for dissolving oxygen in to effluent.

The aeration blower is attached to a 3 HP Crompton greaves motor running at 1440

RPM.

Air blower provides pressurized air, the same is sent through header pipe to diffusers

and oxygen is dissolved in effluent.

For 45 KLD system 32diffusers are required.

This process is to control BOD and COD with certain additives.

Twin lobe blower – roots blower



PP Pump : PP Pump with this system Remi pump 1.5 HP – capable of pumping up

to 5000 liters of effluent per hour, a foot valve is provided at the end of pipe

immersed in ETP tank, Piping provided for this system is UPVC from best of the

manufacturers.

PP Pump

Tube settler : Tube settler is made having two compartments, 2 Mtr X 2 Mtr X 3 Mtr.

(Slant at bottom to collect sludge) It is made of 5mm thick MS plate, welded for leak

proof tests with FRP lining or acid proof coats. This tank is resign coated and is

capable of handling environment corrosions suitable for drug industry. Tube settler is

divided in to two compartments.

The first compartment consists of tube settler media 2 Mtr X 1.7 Mtr X 3 Mtrs and the

second compartment is for collecting pure water. The tube settler is used to arrest

TSS – Total suspended solids. The suspended solids get accumulated at the bottom

of the first compartment. The bottom of the tank from the bottom valve will be

drained once in a week.

Tube settler media – sample



The second compartment receives less TSS effluent water which is collected with

the help of gravity to a raw water storage tank

Proper piping will be provided – CPVC / UPVC for transportation. From the pre – Ro

tank the effluent is now sent to RO plant with the help of a raw water pump.

Reverse osmosis system: RO system in this plant is one of the sub systems and is

very important unit. The process of separation is used to separate dissolved solids

from effluent and provide pure water from RO system. System is designed for 2250

liters per hour capacity for 45 KLD units having 60 % recovery. The reject water is to

be sent to High TDS storage tank for further process.

Reverse Osmosis is the reversal of the natural osmosis process. This process

is used to desalinate aqueous solutions. Using suitable high-performance membranes it is possible today to remove more than 99% of all salts from an aqueous solution.

The water coming out of this RO system is very safe and can be used for process of

company or for gardening.



Basic RO system consists of:

20" long Jumbo Housings 2 Nos.

5 Micron Cartridge Filters - 20" Length (Jumbo) – 2 Nos.

Multistage Pressure Pump -() -

FRP Membrane Housings (Pressure Vessels)-

Membranes - 8" (Imported) - Filmtec

Flow Meters - 5000 LPH

Flow Meters - 10000 LPH

Conductivity / TDS Meter Digital Online

Pressure Guages - 2" dia with S S Glesarin

Low Pressure Switch

High Pressure Switch

Complete Control Panel Board with Powder Coated

Powder coated M S Skid with required pipe and valve fittings (appx)

Pre Treatment for Above Unit:

Raw Water Pump - 2 HP (Kirloskar)

Sand Filter - 16610. Capacity

Sand Bags 40nb Filter Multi Port Valve Side Mount

Carbon Filter - 16610. Capacity

Carbon - 40nb Filter Multi Port Valve Side Mount

Dozing pump 6 ltr/hr capacity e dose RV

100 ltr HDPE Tank



10.4 HAZARDOUS / SOLID WASTE MANAGEMENT

Generation of Hazardous / Solid Wastes

The Hazardous / Solid waste generation will be Distillation residue, by products,

spent carbon, spent oil, ETP sludge, Filter material, ash; Ancillary source will be

discarded drums, bags, containers.

Resource Conservation / Waste Minimization

The unit shall also implement the concept of waste minimization circle including:

Volatiles in the by-products may be condensed and reused.

Volatile raw materials and solvents can be separated by rectification and

these can be recycled into process.

Good House Keeping: Proper housekeeping practices make the system

easier and less costly. Some of these are as follows:

Solid wastes e.g. powders, spills, etc. in process, and packaging are to

be separately collected and disposed off instead of allowing these to join

effluent streams. This will reduce load and increase the efficiency of

treatment system.

Minimizing Hazardous / Solid Wastes Disposal:

The following points are suggested to facilitate Hazardous / Solid wastes disposal:

Efficient collection and transportation mechanism for disposal of solid wastes.

Search for future recycling schemes and evaluate their worth and implement such schemes wherever a promise of economic feasibility exists.

Discarded Container / Barrels/ Liners Management

Discarded containers/ barrels/ liners will be kept at a designated place with

paved surface.

These will be decontaminated (washed/ cleaned) and after that will be

stored in the designated area in scrap yard.

Later on these will be sold to the actual users/ recyclers as per the

Hazardous Waste (Management, Handling and Transboundary Movement)

Rules, 2008.



The record of discarded containers/ barrels/ liners stored in scrap yard

shall be maintained and also, inventory of their selling to the registered

recyclers shall be maintained. The same shall be reviewed by the HSE

Department of the project. The contaminated (without wash/cleaned)

containers/barrels/liners will be dispose off to authorized recycler/ reuser.

HANDLING OF HAZARDOUS / SOLID WASTE AND HAZARDOUS WASTE

The Hazardous / solid wastes will be packed in double lined PP bags and

stored in an isolated room, exclusively ear marked for the purpose. As and

when sufficient stock is accumulated, Organic Waste will be sent to

Cement Industry for incineration and Inorganic will be sent to TSDF for

further treatment and safe land fill.

Industry is entered into an agreement with concerned Hazardous Waste

Management unit

TABLE-10.1: HAZARDOUS / SOLID WASTE GENERATION AND DISPOSAL


Quantity In










Solid Waste Details




10.5 EB [ECOLOGY & BIODIVERSITY]:

The project activity does not require tree cutting during project execution. Also, the

study zone does not have any ecologically sensitive location and hence, the plant

activities are not expected to have any impact on ecology and biodiversity.

Air emissions, liquid effluent disposal and solid waste generation are likely to have

some impact on terrestrial ecosystems. However there will be no net increase in air

pollution.

Treated effluent will be incinerated and solid wastes will be collected and disposed of

properly. Hence, negligible impact on ecology is expected.

Green cover is about 35% of its total area and sufficient number of plants has been

planted.

Management

Raw material dispensing stations will be equipped with vacuum duct hoods with

top cover.

Tanker filling stations will be equipped with in-house designed ducting system

with vapor suction hoods.

All waste storage tanks and waste preparation and raw material storage tanks

will be connected to vacuum system and then to Scrubbing through a fully

automated system with no human interface.

All tanks being used for storage of odorous chemicals/ products/ byproducts will

be connected to vacuum system. Manometers will be provided on these tanks.

The vacuum will be monitored on daily basis and actions will be taken

accordingly.



10.6 SE [SOCIO-ECONOMIC ASPECTS]:

To manufacture bulk drugs is likely to have certain positive impacts on Socio-Economic Environment

Positive impacts:

Employment generation potential of the project will be for about 50 persons,

wherein the First preference will be given to the Qualified People from within

the Study Area.

Various modes of indirect employment i.e. providing Conveyance,

Transportation, Services & Goods will also increase.

Overall improvement in quality of life of people of the study area will

drastically increase.

10.7 HG [HYDROGEOLOGY, GROUND WATER & WATER CONSERVATION]:

The proposed manufacturing unit is located on the divide portion of the catchment

and is over the run off zone. No major streams are passing through the site. The

catchment area of the proposed site is small and recharge conditions are moderate.

However, the buffer zone of 10Kms radius has good catchment and recharge

potential with streams and tanks of considerable storage potential.

All the stream courses are ephemeral in character and carry large volumes of storm

flows during rainy season and remain dry during non - monsoon season. The

present stage of ground water development in the district is 61% in non-command

and 12% in command area with overall stage of ground water development of 36%.

All the mandals are falling in safe category, contrary to 10 over exploited 4 critical

mandals during 2004-05. The stage of development is generally high in area

occupied by sedimentaries, while it is low in canal command areas, suggesting the

need for judicious exploitation of ground water resources in future.

Ground Water Conditions

Ground water occurs under unconfined, semi to confined conditions in different

formations of the area. In the crystalline formation the yield of the open wells range

from 20 – 50 m3 /day and the discharge of bore wells vary from 17.28 to 648 m3/day.

Eight bore wells and two dug wells were inventoried to assess the groundwater

conditions. The depth to water levels was found to be 4-14.96m bgl. The quality of



water is found to be potable. Ground Water development is limited in alluvium and in

general the deeper zones are brackish to saline in nature. In general, the ground

water is suitable for drinking and irrigation purposes in crystallines, sedimentaries

while that occurring in alluvium the water is not suitable purpose and irrigation

purpose under ordinary conditions. The water table gradient is steep in northern part

and is very gentle in southern part and the direction of ground water flow is towards

southeast.

As the extent of the proposed site is small, only roof top rainwater harvesting is

suggested for improving recharge to the groundwater. Also, in conjunction with local

government authority’s water harvesting measures like de-silting of tanks, Check

dams and percolation pits are proposed to augment the declining water levels. The

monitoring locations are tabulated below and depicted on the map annexed.

Possible Impact on Groundwater & Mitigation

1) The generation of fly ash from the proposed industry will have sedimentation

affect over the wind ward side on the soil regime as well as the buffer zone

over a period of time affecting the Green cover/ plantation thereby affecting

the growth of plants / crops for which the generation should be arrested at the

origin.

2) The chemically loaded waste water leakage from the proposed industry will

adversely affect the soil, surface and groundwater and the prevention

suggested is not to allow the waste water leakage from the industry.

3) All the chemically charged liquid discharges should not be allowed to be in

contact with surface/ groundwater which will have adverse affect on their

quality. As such the contact should be avoided completely at source.

10.8 GEO [GEOLOGY]:

The district is underlain by Archaean crystallines, Gondwanas, Deccan Traps,

Tertiaries and alluvial sediments. About 45% of the district is underlain by Gondwana

formations, 40% is underlain by Alluvium and the rest is by Archaean crystalline

rocks.



10.9 SC [SOIL CONSERVATION]: One of the adverse impacts of a project may be enhanced soil erosion. Any plan or

activity or action that is capable of preventing soil erosion is capable of conserving

soil. Soil erosion is mainly on account of rain and flood. Soil erosion is due to heavy

rains and floods coupled with improper and unplanned land use. The damage due to

rains and floods can be minimized with appropriate prevention and mitigation

measures. The second asp Plan for conservation of soil is site - specific. Action plan

for soil conservation should take in to account the following criteria and

considerations:

i) Soil: Extent or area of vacant land; topography of soil; slope or gradient;

texture, structure and composition of soil; land use and land cover;

connectivity with the adjacent land mass

ii) Rainfall: Intensity and frequency of rainfall and drainage.

Based on the above, engineering or biological or integrated land, water and

afforestation programme are designed. Measures for prevention of surface runoff

and water conservation are capable of preventing soil erosion.

10.10 RH [RISK & HAZARDS MANAGEMENT]:

All the provisions as per the Factories act, 1948 manufacture, storage and import of

hazardous chemicals [MSIHC] Rules, 1989 and amendments thereafter and also,

the hazardous and other wastes [Management and Tran boundary Movement]

Rules,2016 to be followed.

Work environment monitoring as well as noise monitoring is carried out on regular

interval through third party. Dedicated occupational Health center is available with

various facilities. Round the clock Ambulance is available equipped with necessary

first aid facility.

Following hazards may occur during the operation

Fire Hazards

Chemicals handling and Storage

Road accidents

Process hazards

Health hazards



Following procedures will be followed for effective management of any disaster in

the plant.

Identification of disaster risk

Identification of persons at risk

Removal of hazard

Evaluation of the risk

Control measures to be taken

Maintaining assessment records

Management of Occupational Health &Safety of Employees & Visitors

Prefer an integrated approach and make environmental management a part of

overall environmental, health and safety [EHS] management system.

This model EHS system suggests and addresses EMS issues such as:

Management system expectation

Management leadership, responsibilities and accountability

Risk assessment and management

Compliance and other requirements

Personnel, training and contractor services

Documentation and communications

Facilities design and construction

Operation ,maintenance and management

Community awareness and emergency response

EHS performance monitoring and measurement

Incident investigation reporting and analysis

EHS management system audit

Management review and audit

Direct exposure to the Bulk Drugs or raw materials may affect the health of the

employees. Hence direct exposure to the product is eliminated by providing closed

handling facilities with pumps and pipelines in the process plant. Personal protective

equipment viz. Hand gloves, safety goggles, nose masks, and safety helmets are

provided to all the employees working in the plant. Company has a policy of



providing protective equipment for all personnel including contract and casual

workers.

In order to safe guard the health of the employees, all the employees undergo

periodic health checkup. All the employees will be trained and educated periodically

about the hazardous nature of chemicals used in the process.

Worker exposure to chemicals can occur during manufacturing when chemicals spill,

leak, or discharge from the process system and contaminate areas where workers

are present. The most frequently reported industrial exposure occurs during the

transfer of materials. The entry of workers into systems, equipment, or enclosures

that are contaminated may occur inadvertently, but routine servicing, nonscheduled

maintenance, and process monitoring appear to be the kind of activities with

potential for significant exposure.

All raw materials, intermediates and finished products are handled in completely

closed system using Pumps, Vacuum systems and Pipelines. All precautions are

taken during design stage itself, to completely eliminate the risk of any kind of

exposure. As an additional safety measure, Personal protective equipment viz. Hand

gloves, safety goggles, nose masks, and safety helmets are provided to all the

employees working in the plant.

10.11 GREENBELT DEVELOPMENT

10.11.1 OBJECTIVE

The purpose of a green belt around the plant site is to capture the fugitive emissions,

attenuate the noise generated and improve the aesthetics.

Environmental protection has been considered as an important domain for industrial

and other developmental activities in India. Ministry of Environment, Forest and

climate change (MoEF&CC) has taken several policy initiatives and promoted

integration of environmental concerns in developmental projects. One such initiative

is the notification on Environmental Impact Assessment (EIA) of developmental

projects issued in 1994 and further revised notification in year 2006 under the

provisions of Environment (Protection) Act, 1986 EIA Guidance Manual for building,

construction, townships and area development projects proactively talks about the

importance of greenbelts in such projects.



Greenbelt in India refers to a buffer zone created beyond which industrial activity

may not be carried on. This concept has developed through a long line of cases and

today, greenbelts are present not only for the purpose of protecting sensitive areas

to maintain ecological balance, but are also be found in urban areas so as to act as a

sink for the harmful gases released by vehicles and industries operating in the city

area. In this regard, comprehensive Guidelines for Developing Greenbelts have been

compiled by the Central Pollution Control Board [Refer Probes/75/1999-2000].

As per the stipulations of MoEF&CC, greenbelt is to be provided all along the

boundary by planting tall, evergreen trees and the total green area including

landscaping area will be 1/3rd (About 33%) of the plant area. This will include Lay

down area which will be later on converted into Green area. Depending on the size,

activity and environmental impacts of the industry; extent of land available, agro

climatic conditions, at least 5 m wide greenbelt of one two rows of tall and evergreen

plants should be grown at the rate of 1500 to 2000 per Ha.

The proposed greenbelt is neither adequate nor it meets the standards of an

industrial greenbelt. It is envisaged to develop greenbelt on all sides of the industry

in an area of about 2.45 Acres (9914.8 SQM). Additional rows of saplings of 1 to 2

year age will be planted at distance of 2 m x 3 m @ 1500 per Ha in the blocks. All

dead trees will be removed and replaced. Work on reinforcement and strengthening

of the greenbelt shall be undertaken soon after the construction of compound wall.

An amount of Rs. Rs.5, 00,000 /- for greenbelt. The amount will be spent during the

period of five years. First year amount will be Rs.2, 00,000 for plantation. Second

year amount will be Rs.1, 00,000/- for development of plants. Third year amount will

be Rs. 1, 00,000/- for maintenance and development. Fourth & Fifth year amount will

be Rs. 50,000/- & Rs. 50,000/- for development. Thereafter, the Environment

management cell will take care of maintenance. In site area 1500 plants will be

grown in two rows of 3mx2m all along the boundary besides one row of avenue

plantations on either side of the internal roads at a distance of 5m from plant to plant.

A list of plants suitable for greenbelt and to the local agro climatic conditions.

A suggested list of plants identified for greenbelt and avenue plantations. (Hamata

grass shall be grown as ground cover under the trees for soil and nutrient

conservation and fodder production) is given in Table 10.2



TABLE -10 .2: LIST OF PLANTS FOR GREENBELT

Botanical name Local or common name Importance Alstonia scholaris Devil’s tree Ornamental tree Acacia auriculiformis Australian wattle Avenue tree Albizia lebbeck Dirisana Shade and timber Anthocephalus indica Kadamb Shade and timber Azadirachta indica Vepa or Neem Multipurpose Dalbergia sissoo Sissoo Avenue and timber tree Dendrocalamus strictus Bamboo Bamboo products Grevillea robusta Silver Oak Erect non shedding tree Holoptelia integrifolia Nemali naara Fibre and timber Leucaena leucocephala Subabul Fodder and pulp wood Mangifera indica Mango Edible fruit Millingtonia hortensis Aakasa malle Ornamental tree Mimosops elengi Pogada Shade and edible fruit Muntingia calabura Wild cherry Shade and edible fruit Peltophorum pterocarpum Copper pod Shade only Pongamia pinnata Gaanuga Source of biodiesel Polyalthia pendula Ashoka Majestic tree Polyalthia longifolia Ashoka Avenue tree Samania saman Nidrabhangi Shade, timber & fodder. Spathodea companulata Flame of the forest Ornamental avenue tree Syzygium cumini Neredu Edible fruits Tamarindus indica Chinta Tamarind fruit and leaf Terminalia arjuna Nallamaddi Timber and shade tree Terminalia catappa Baadam Edible nuts Stylosanthes hamata Hamata grass Fodder and nitrogen fixing

legume

10.12 POST PROJECT MONITORING

Regular monitoring of all significant environmental parameters is essential to check

the compliance status vis-à-vis the environmental laws and regulation. The objective

of the monitoring will be as follows.

To verify the results of the impact assessment study with respect to the

proposed projects

To study the trend of concentration values of the parameters, which have

been, identified as critical and planning the mitigate measures.

To check and assess the efficacy of pollution control equipment.

To implement the EMP, a structured Environment Management Cell (EMC)

interwoven with the management system will be created.



EMC will undertake regular monitoring of the proposed pollution control

system and conduct yearly audit of the environmental performance of the

system. It will also check that the stipulated measures are being satisfactory

implemented and operated.

A comprehensive environmental monitoring program that has been prepared for the

purpose of implementation in the proposed for manufacturing bulk drug industry by

the EMC is described below.

10.12.1AIR POLLUTION MONITORING

The Stack emissions from the DG Sets shall be monitored once in a month for PM10,

NOX & SO2. The ambient air at the plant site shall be monitored once in a month for

PM10, NOX & SO2. The Fugitive Emissions like VOCs shall be monitored in

Production block, Raw Material and Finished goods section.

10.12.2 WASTE WATER MONITORING

The quantity of waste generated from ETP unit will be regularly measured using flow

meters. Wastewater samples will be collected and analyzed for critical parameters

like pH, TDS, BOD, COD, Oil and Grease, Chlorides, Sulphates etc., The frequency

of monitoring will be daily.

10.12.3GROUND WATER MONITORING

Ground water quality of bore well will be regularly monitored preferably once in 12

months.

10.12.4 HAZARDOUS / SOLID WASTE MONITORING

Hazardous / Solid waste generated from the plant will be monitored once in a month

/ change of the product.

TABLE- 10.3: THE DETAILS OF THE MONITORING PROGRAM

S. No Type of Monitoring

Location of Monitoring

station

Frequency of

Sampling

Duration of

Sampling Instrument Parameters

to be test

1 Ambient Air 3 Places at 120o

angle Once in a month

8 hrs/24 hrs RDS PM10, SO2,

NOX

2 Work room concentration

Production Block, Store rooms, Solvent Yard

Once in 3 Months --- Personal

Sampler VOC’S & Solvents

3 Stack Monitoring

Boilers, D. G. Sets, Scrubber

Once in a month --- Stack

Monitoring PM10, SO2, NOX and



vents Instrument Scrubbing gases.

4 Noise Levels

D. G. Sets, Compressors, Chillers, Boiler section, Production block, Admin. block, ETP area, Open area etc.

Once in a month --- Noise meter

Day – Night Noise levels in Leq

5 Effluent

Raw HTDS & LTDS effluent, Condensate, Treated wastewater

Daily --- Lab

Physical and Chemical Parameters 6 Ground water Nearest Bore

well Once in six months ---

7 Solid Waste Sludge from Process, ETP

Once in six months ---

All the above observations will be complied and documented by the EMC to serve

the following purposes.

Identification of any environmental problems that are occurring in the area.

Initiating or providing solution to those problems through designed channels

and verification of the implementation status

Controlling activities inside the plant, until the environmental problem has

been corrected.

Suitably responds to emergency situations

The industry will engage recognized laboratories to carry out all necessary

monitoring parameters. Qualified staff has been appointed for the purpose of

Operation and maintenance of the pollution control facilities. Stand-by facilities are

provided to all the facilities so as to ensure fail proof treatment.

10.13 MANAGEMENT OF PUBLIC INTERESTS 10.13.1OBJECTIVE

To assure the neighbouring communities that the promoters and management have

high consideration for the welfare of this region, the following commitments are made

by the project promoters.



10.13.2 PREFERENCE TO LOCAL POPULATION

For the recruitment of semi-skilled and unskilled workers preference will be given for

the local people.

10.13.3 HEALTH CAMPS

Health camps will be organized along with the local administration, voluntary

organizations like Red Cross, Rotary Club etc. in the surrounding villages.

10.13.4 PUBLIC AMENITIES

The management will support the local administration with funds and other forms of

assistance for the development of public amenities in this region.

10.13.5 PUBLIC RELATIONS The management will set up a public relations office to maintain to good line of

communication between the management and the public on matters of

environmental concern.

10.14. ENVIRONMENTAL MANAGEMENT

Vensar Laboratories Pvt. Ltd. proposes to manufacture Products along with its

Therapeutic category details are given below Table10.4.

TABLE- 10.4: LIST OF PRODUCTS (MANUFACTURING CAPACITY WITH THERAPEUTIC CATEGORY)

S. No Product Name


Application

Quantity In

Kgs/Month

Quantity In

Kgs/Day 1 Carvedilol Cardiovascular 5000.00 166.67

2 Citalopram Hydro Bromide Antidepressant 2000.00 66.67

3 Ketrolac tromethamine Anti-inflammatory 5000.00 166.67

4 Ramipril Cardiovascular 5000.00 166.67

5 Sertraline Hydrochloride Antidepressant 5000.00 166.67

6 Terbinafine Hydrochloride Antifungal 4000.00 133.33

7 Tramadol Hydrochloride Analgesic 5000.00 166.67

Total 10000.00 333.33



10.15 PROJECT DETAILS Vensar Laboratories Pvt. Ltd. proposes to establish a Bulk Drug & Intermediates

manufacturing unit at Survey No. 32, Tupakulagudem Village, Tallapudi Mandal,

West Godavari District, Andhra Pradesh.

The industry proposes to establish unit in an area of 7.00 Acres (28328.00SQM) with

investment of 6.00 Crores. The Industry is having its administrative office at

Duplex No:12,lakshmi Gayatri Enclave, Aditya Nagar, KPHB, Kukatpally, Hyderabad.

Gopavaram village is at a distance of 1.43 KMs in N Direction from the site.

Kovvuru is a Town; it is at a distance of 20 KMs in SE side from the project

site.

Site is at a distance of 28 KMs from Rajahmundry in SE direction.

Nearest State Highway from the site is SH-42 (Koyyalagudem - Nallajerla

road) at a distance of 17 KMs in E side from the project site.

Nearest National Highway from the site is NH-5 (Rajahmundry-Anakapalle) at

a distance of 26 KMs in SE side from the project site.

The co-ordinates of the proposed location are Latitude: 17009’30.20” North

and Longitude: 81035’23.36” East.

10.16. PROCESS PLANT AND MACHINERY

The Plant and Machinery consists of Process Reactors, Centrifuges, Condensers,

Heat exchangers, Packing materials and Laboratory equipment required for the

plant. The Plant will be designed to meet the requirements of GMP and all the

required ventilation facilities will be provided.

10.17 AUXILIARY PLANTS

In addition to the above process plant, the unit will have auxiliary plants like water

demineralization plant, steam boiler, cooling water system, diesel generators,

wastewater collection tanks, etc. to support the process operations.

10.18 RESOURCES AVIALABLE WITH THE PROJECT 10.18.1 LAND AREA

The proposed plant is having site in an area of 7.00 Acres (28328.00SQM). The

plant area falls at the intersection of Latitude: 17009’27.76” North and Longitude:

81035’32.23” East. The nearest railway station is Kovvur Railway Station which is



around 22 KMs from the unit and the major railhead is Rajahmundry. The National

Highway NH-5 connecting Rajahmundry with Anakapalli is around 26 KMs (SE) from

the plant site. Industry proposing to provided more than 33% area (recommended by

MoEF&CC) for Greenbelt development with various species.

TABLE 10.5: LAND USE DETAILS OF PLANT SITE

S. No Description Area (SQM)

Area (Acres)

1 Built up land 10764.64 2.66 2 Greenbelt area 9914.8 2.45 3 Roads area 5382.32 1.33

4 Open area/Parking 2266.24 0.56

Total 28328.00 7.00

More than 33% area (recommended by MoEF&CC) for Greenbelt development. 10.18.2 WATER REQUIREMENT The total water requirement of the Plant is 79.71 KLD. The breakup of water required is given here under. Industry will be drawn the water from Bore Wells.

TABLE- 10.6: WATER CONSUMPTION DETAILS

S.No Purpose Water consumption In KLD


Total 79.71




TABLE- 10.7: WATER CONSUMPTION – PRODUCT WISE IN PROCESS

S. No

Product Name

Production Capacity kg/Day

Water Input

Kg/Day 1 Carvedilol 166.67 233.33 2 Citalopram Hydro Bromide 66.67 166.67 3 Ketrolac tromethamine 166.67 14066.67 4 Ramipril 166.67 50.00 5 Sertraline Hydrochloride 166.67 233.33 6 Terbinafine Hydrochloride 133.33 271.67 7 Tramadol Hydrochloride 166.67 14143.33

Total (Worst combination of any two products on campaign basis only 333.33 28210.00

10.18.3 RAW MATERIAL REQUIREMENT

The raw materials of the plant are the chemicals, solvents and the fuels. The

chemicals required for the process are bought from the local market. The list of the

chemicals required with their quantity, physical nature is given in Chapter-II. Coal is

used in the boilers and is sourced from the local traders. The Coal consumption is

about 15 TPD. High Speed diesel is used in D.G. Set, which is about 80 Liters /hr

and D.G. Set is operated only during power failures.

Some solvents will be stored in HDPE drums on raised platform under roof and few

solvents will be stored in storage tanks. The other raw materials will be stored in the

store room as the per the safety norms.

STORAGE AND TRANSPORTATION OF RAW MATERIALS

Raw materials will be received by trucks and tankers .The same will be stored in

over storage rooms it is stored under lock and key in designated storage area. The

chemicals will be received in Fiber drums, HDPE drums, and PP bags.

10.18.4 POWER REQUIREMENTS

Power requirement of the plant is proposed to be 300 KVA.

A DG set 250 KVA is proposed which will be used during power failures.

10.19 PROCESS DETAILS 10.19.1 PROCESS DESCRIPTION AND MATERIAL BALANCE Process description and Material Balance for all the products are given in Chapter II.



10.20 POLLUTION LOADS 10.20.1 AIR POLLUTION LOADS - PROCESS EMISSIONS

Process emissions are which is liberated from manufacturing process of

proposed products.

HCl, HBr, CO2, O2, H2 liberated from the process. In these Process emissions,

some gaseous emissions are Polluting & none polluting.

Polluting gases like HCl (15.00 Kgs/day), HBr (45 Kgs/day) are disposed

through scrubbers.

Non polluting gases like O2 (29.00 Kgs/day) emissions will be dispersed into

atmosphere, H2 (05.00 Kgs/day) emissions diffused by using Nitrogen through

Flame arrestor & CO2 (09.00 Kgs/day) emissions will be dispersed into

atmosphere.

Product wise Process Emissions & fugitive emissions are given in table 10.9 &10.10

TABLE- 10.8: PROCESS EMISSION DETAILS


Disposal Method





TABLE- 10.9: PROCESS EMISSION DETAILS PRODUCT WISE

S.No. Product Name Prod/ Day

Gases per Day CO2 H2 O2 HCl HBr

1 Carvedilol 166.67 0.00 0.00 0.00 15.00 0.00

2 Citalopram Hydrobromide 66.67 0.00 0.00 0.00 0.00 0.00

3 Ketorolac Tromethamine 166.67 0.00 0.00 0.00 0.00 0.00 4 Ramipril 166.67 0.00 0.00 0.00 0.00 0.00 5 Sertraline Hydrochloride 166.67 0.00 2.97 0.00 0.00 0.00

6 Terbinafine Hydrochloride 133.33 8.98 0.00 0.00 0.00 0.00

7 Tramadol Hydrochloride 166.67 0.00 1.83 28.90 0.00 45.00

Total 8.98 4.80 28.90 15.00 45.00



10.20.2 PROCESS EMISSION CONTROL SYSTEM

a) No. of scrubbers and capacity : 2 No. scrubbers installed.

1 No: 300mm X 4 meter

1 No: 300 mm X 3 meter

b) Type of scrubber : ID with water circulation

C). Chemical used in scrubber : Water/Alkali/ solution

FIGURE- 10.7: SCHEMATIC DIAGRAM OF EMISSION CONTROL SYSTEM

10.20.3 FUGITIVE EMISSIONS

Various types of solvents are used in the Bulk Drugs manufacturing process. The

solvents are stored in storage tanks with vent condensers. These are handled in

closed conditions. The industry will take measures for reduction of fugitive emissions

by providing chilled brine circulation to the condensers which, ensures the recovery

of 95% .Good ventilation will be provided to reduce the workroom concentrations.

The reactor generating solvent vapors will be connected to condensers with reflux



system. Dyke walls will be provided to the solvent storage yards. A product wise

solvent detail is given in the Table 10.10.

The solvents like. Acetone, Ethanol etc will be recovered up to 95 % by using

distillation.



TABLE- 10.10: DETAILS OF FUGITIVE EMISSIONS [PRODUCT WISE]


capacity Kg/Month

Solvent Name

Quantity in Kgs/Day

Solvent Input

Solvent Recovery

Solvent Loss

Solvent in waste water Solvent in Residue

Kgs/Day Kgs/Day Kgs/Day Kgs/Day Kgs/Day 1 Carvedilol 5000.00 Ethyl actetate 266.67 253.33 13.33 0.00 0.00

Toluene 333.33 316.67 16.67 0.00 0.00

THF 300.00 285.00 15.00 0.00 0.00

Total 900.00 855.00 45.00 0.00 0.00 2 Citalopram Hydrobromide 2000.00 Toluene 41.67 39.50 2.17 0.00 0.00

Acetone 83.33 79.17 2.50 0.00 0.00

Total 125.00 118.67 4.67 0.00 0.00 3 Ketorolac Tromethamine 5000.00 Acetone 666.67 586.67 30.00 0.00 50.00

Total 666.67 586.67 30.00 0.00 50.00 4 Ramipril 5000.00 Ethyl acetate 200.00 190.00 10.00 0.00 0.00

Ethanol 216.67 206.00 10.67 0.00 0.00

Total 416.67 396.00 20.67 0.00 0.00 5 Sertraline Hydrochloride 5000.00 Ethyl acetate 666.67 633.33 33.33 0.00 0.00

Diisopropyl alcohol 200.00 190.00 10.00 0.00 0.00

Total 866.67 823.33 43.33 0.00 0.00 6 Terbinafine Hydrochloride 4000.00 Toluene 133.33 126.67 6.67 0.00 0.67

IPA 100.00 95.00 5.00 0.00 0.00

Total 233.33 221.67 11.67 0.00 0.67 7 Tramadol Hydrochloride 5000.00 Methanol 666.67 591.67 30.00 0.00 45.00

Total 666.67 591.67 30.00 0.00 45.00

Grand Total 10000.00 1766.67 1678.33 88.33 0.00 95.00



10.20.4. EMISSIONS – UTILITIES



local authorized sources, and the company is proposing 2,00,000 K. Cal / Hr.

Thermo pack Agro Waste fired/ Coal fired Boiler.

Proposing 250 KVA DG sets for usage during the power failures. The emission

details are presented in below table No.10.11 & 10.12

TABLE-10.11: EMISSION CHARACTERISTIC DETAILS OF BOILER



Type of Fuel -- Indian Coal/Agro waste Coal Consumption TPD 15.0 Ash Content % 47 Sulphur Content % 0.8 Nitrogen Content % 1.07 No. of Stacks No 1 Height of stack m 32 Diameter of Stack m 0.60 Temperature of Flue Gas oC 110 Velocity of Flue Gas m/s 8.50 Particulate Matter at outlet of Bag filter (Based on 115 mg/Nm3 at outlet)

gm/sec 0.62

Sulphur dioxide emission gm/sec 1.39 Oxides of Nitrogen emission gm/sec 1.86

Pollution control equipment - Cyclone separator

followed by suitable pack of Bag filters

TABLE-10.12: STACK EMISSION DETAILS FOR THERMO PACK BOILER


(Proposed) Thermo pack Boiler Capacity K. Cal /Hr. 2,00,000 Type of Fuel -- Agro waste / Coal Stack Temperature Before Air preheater

oC 250


oC 180

Combination Air Temperature oC 120 Efficiency Increased By % 5



Stack Height m 9.0 Fuel Consumption per Day TPD 2.0 Diameter m 0.5

TABLE-10.13: STACK EMISSION DETAILS FOR DG SETS

Capacity In KVA

Emission of SPM

in mg/Nm3



Stack dia. In m

Flue Gas

Temp. in OC

Stack Height in m

Flue gas Velocity

In m/sec.

250 KVA (Proposed)

58.0 24.0 30.0 0.30 250 10 18.24

10.20.4 WASTE WATER LOADS TABLE- 10.14: WASTEWATER GENERATION

EFFLUENT GENERATION DETAILS

S. No Purpose Effluent In KLD

1 Process 28.60 2 Washings 2.00 3 Boiler Blow down 4.00 4 Cooling towers Blow down 2.00 5 Scrubbing system 1.00 6 Domestic 2.40 Total 40.00

TABLE- 10.15: HTDS & LTDS DETAILS

Unit HTDS KLD

LTDS KLD

Effluent Generation

in KLD

Treatment Method

Process 21.00 7.60 28.60 HTDS effluent sent to ETP with MEE System LTDS effluents treated in ETP – RO Plant / RO Rejects to MEE System and RO permeate to reuse, Condensate from MEE to reuse and MEE residue to ATFD.


Scrubbing system 1.00 0.00 1.00 Domestic 0.00 2.40 2.40 Septic tank followed by soak pit

Total 22.00 18.00 40.00



The pollution loads for various pollutants viz., TDS, Inorganics, Organics; COD for

individual products was worked out based on the material balance. The total

wastewater pollution load is presented in the following table.



TABLE- 10.16: WASTEWATER GENERATION - PRODUCT WISE

S.No Product Name Production Capacity

Effluent Details

Water Input

Water In Effluent

Inorganics in water

Organics in

water TDS COD HTDS LTDS Total

Effluent Kg/Month Kg/Day Kg/Day Kg/Day Kg/Day Kg/Day Kg/Day Kg/Day Kg/Day Kg/Day

1 Carvedilol 5000.00 233.33 233.33 16.67 0 16.67 0 183.33 66.67 250

2 Citalopram Hydrobromide 2000.00 166.67 169.67 1.67 0 1.67 0 88.00 83.33 171.33

3 Ketorolac Tromethamine 5000.00 14066.67 14066.67 43.67 0 43.67 0 6777.00 7333.33 14110.33 4 Ramipril 5000.00 50.00 57.38 0 0 0 0 0.00 57.38 57.38 5 Sertraline Hydrochloride 5000.00 233.33 233.25 247.83 0 247.83 0 447.74 33.33 481.07

6 Terbinafine Hydrochloride 4000.00 271.67 275.34 0 0 0 0 0.00 275.34 275.34

7 Tramadol Hydrochloride 5000.00 14143.33 14110.9 102.9 0 102.9 0 14213.80 0.00 14213.8

Total (Worst combination of Any two products) 10000.00 28210.00 28177.57 350.73 0.00 350.73 0 20990.80 7608.67 28599.47



10.20.5 STAGEWISE EFFLUENT CHARACTERSTICS

The stage wise effluent characteristics have been arrived for the proposed products

based on the material balance, which is given in Chapter-II

10.21 HAZARDOUS / SOLID WASTE

The detail of the Hazardous/Solid waste generation is listed in the following table.

TABLE- 10.17: HAZARDOUS/SOLID WASTE & HAZARDOUS WASTE GENERATION, DISPOSAL DETAILS


Quantity In










Solid Waste Details


Hazardous/Solid waste will be segregated. Detoxified containers, HDPE Drums/Bags

will be stored in the covered and raised platform with Leachate collection system and

disposed to authorized parties. Non incinerabale solid waste will be disposed to

TSDF for secured landfill.

The Hazardous/Solid waste should be disposed off through 6-copy manifest system

within 90 days from the generation. All records will be maintained properly.

The Hazardous/Solid waste generated per day product wise is given below



TABLE- 10.18: HAZARDOUS/SOLID WASTE GENERATION – PRODUCT WISE

S.No Product Name Production Capacity

Solid waste Details

Organic Inorganic Spent carbon

Total solid waste

Kg/Month Kg/Day Kg/Day Kg/Day Kg/Day 1 Carvedilol 5000.00 0.4 166.67 6.67 173.74

2 Citalopram Hydrobromide 2000.00 0.4 0.00 0.83 1.23

3 Ketorolac Tromethamine 5000.00 335.67 0.00 3.33 339.00

4 Ramipril 5000.00 3.95 0.00 0.00 3.95

5 Sertraline Hydrochloride 5000.00 1.44 203.33 0.00 204.77

6 Terbinafine Hydrochloride 4000.00 0.34 0.00 0.83 1.17

7 Tramadol Hydrochloride 5000.00 333.33 0.00 8.33 341.66

Total (Worst combination of Any two products) 10000.00 669.00 370.00 15.00 1054.00

10.21.1 HAZARDOUS/SOLID WASTE CHARACTERISTICS

Estimated Hazardous/solid waste characteristics as following table

S. No Parameters Unit Organic Residue

Inorganic solid waste

ETP Sludge

Spent Carbon

1 pH - 6.0 -7.5 8.0 - 8.5 7.0 -7.5 7.0 -8.5 2 Bulk density g/cc 1.12 1.05 1.0-1.5 -

3 Calorific value K.cal/kg 2500 - 3500 < 250 < 250 >2500

4 Flash point 0C <65 >65 >65

5 Loss on drying at 111-1050C %W/W 18-20 20-25 40-70 -

6 Loss on Ignition 5500C (Dry Basis)

%W/W 50-80 16-20 10-15 -

7 Water Soluble Compounds %W/W <10 >10 >10 -

8 Oil and Grease (As n-Hexane Extractable)

%W/W >10 <10 <10



10.22 ROOF WATER HARVESTING

To augment the declining ground water levels and water harvesting is the need of

the hour.

Rainwater harvesting is a mechanism involved in collecting, storing and using. A

rainwater harvesting system comprises various stages – flow of rainwater through

pipes or drains, filtration and storage in tanks for reuse or recharge. There are five

components in rainwater harvesting namely catchment, conveyance, filtration,

storage and recharge.

Roof top area is considered for harvesting rainwater for this project and other areas

are excluded due to possibility of chemical contamination. Roof top rainwater

harvesting is one of the appropriate options for augmenting ground water recharge/

storage in urban areas where natural recharge is considerably reduced due to

increased urban activities and not much land is available for implementing any other

artificial recharge measure. Roof top rainwater harvesting can supplement domestic

requirements in rural areas as well.

Design of Roof Water Harvesting Structure

Quantity of Rain water collection and recharging depends upon

Average rainfall

Catchment area

Run-off coefficient

Infiltration rate

Evapo Transpiration

Porosity

Permeability

Generally used Rain water harvesting structures are like Recharge Pits, Invert Well,

Surface storage pond (where areas are large and Optimum rainfall), Check Dams,

Nalla Bunds.

The rain water from the Roof top will be collected through PVC pipes and transferred

to the proposed rainwater harvesting pits through steps of eliminating suspended

particles, oil & grease through finally to the ground.

Science the area of harvesting is small the above parameters are not studied in

detail and only applicability as to conserve and harvest the available quantum is

considered and suitable structure suggested.



Based on the Central Ground Water Board Data for West Godavari District, Normal Annual Rainfall = 1078 mm (1.078 m)

TABLE-10. 19: AVAILABLE RAINWATER (ANNUAL) FOR HARVESTING

Description Area (m2) Rainfall (m/Annum)

Runoff coefficient

Total Rainwater (m3/Annum)

Roof Area 10764.64 1.078 0.8 9283.42

Total available rainwater (in m3/annum)

Details of Rainwater harvesting pits:

Number of pits 03 No.

Size of pits 6.5 m x 3.5 m x 3m

Size of Bore 350 mm dia.

Size of pipe 150 mm dia.

FIGURE-10.9: ROOF WATER HARVESTING STRUCTURE



10.23 INVESTMENT

The proposed total gross investment in Buildings and Plant & Machinery will be

approximately Rs. 6.00 Crores and the unit has been registered under SSI

Category. Industry will allocate an amount of about Rs. 100 Lakhs for Environmental

Protection measures. Recurring cost will be about Rs. 19 Lakhs per annum.

10.23.1 BUDGETARY ALLOCATION

The management will be set aside adequate funds in its annual budget to fully meet

the stated objectives of the environmental policy. The capital equipment for

environmental management include effluent treatment plants, pipelines and channels

for waste water discharge, green belt development and the environment laboratory.

TABLE- 10.20: PROPOSED BUDGETS FOR ENVIRONMENTAL MANAGEMENT PLAN [EMP]

S. No Particulars Proposed

Capital Cost (Rs. Lac)

Recurring Cost

(Rs. Lac)

1 Pollution Control Equipment (Scrubbers, Cyclone separator, Bag filter , Sampling port arrangements etc.,)

5.0 1.0

2 ZLD System (MEE , RO, necessary modification of ETP system)

85.0 12.0

3 Rain Water Harvesting (Roof top water collection pit and Roof top water towards the rain water harvesting pit)

3.0 0.0

4 Green Belt Development (Plantation and Maintenance) 4.0 1.0

5 Health & Safety (PPEs, Medical Surveillances Expenses etc.,) 3.0 3.0

6 Environmental Monitoring (Air, Water, Noise, VOCs, Boiler Stack flue gases, DG sets stack monitoring expenses etc.,)

0.0 2.0

Total 100 19 10.24 OCCUPATIONAL SAFETY AND HEALTH ASPECTS

There will be few gaseous emissions generated or released from the manufacturing

process. The industry will be provided the efficient scrubbers for controlling the

gaseous emissions and plant will be well ventilated to improve the work zone

environment and layout is worked out in such a way that the workman works in a

comfortable atmosphere by using adequate personal protective equipment. Industry

will be taking all precautions to minimize the fugitive emissions on handling of



various solvents and chemicals etc. Sufficient fire extinguishers and fire hydrants will

be provided in the plant to handle any emergency.

Full-Fledge Treatment and MEE system will be provided for treating the effluents

generated from the proposed activity. Full-Fledge Treatment facility will be

constructed above ground level to prevent seepage.

First aid kits will be provided in all the departments and training on First aid will also

provide to all the employees for early treatment.

Candidates to be recruited to work in the factory shall be subjected to pre

employment medical checkup. Only those certified to be medically fit should be

recruited. Candidates on recruitment safety training will be given for one week on

handling of chemicals

Vensar Laboratories Pvt. Ltd will strictly follow the safety norms as per the

guidelines of the National Safety Council for a process industry and will provide all

the necessary safety equipment for the protection of the Industrial establishment as

well as the personnel working in the plant premises. Personnel Protective Equipment

will be provided to all its employees who are involved in the handling of hazardous

activities. The storage and handling of various chemicals will be according to the

norms of MSDS and the Inspector of Factories. Personnel involved in the production

will be provided with protective clothing, helmets, goggles, masks, gloves, etc.

These handling operations will be carried out under the strict supervision of the

trained and highly skilled personnel. Supervision will be provided to ensure the

usage of these PPE’s. Necessary fire fighting facilities like extinguishers, sand

buckets, etc. will be provided to meet the on-site emergencies. A detailed On-site

Emergency plan will be prepared and implemented complying the provisions of

Factories Act. An agreement with a nearest hospital for treating the employees due

to unforeseen emergencies will be entered into.

10.25 SOCIO-ECONOMIC DEVELOPMENT ACTIVITIES

Socio-Economic Development activities will be implementing in coordination with the

NGOs, Village Panchayats, and other Governmental Entities.



A. Social Activities:

Health check up camps and Medical facilities to Infants and senior citizens,

free medicine supply etc., will be provide on regular basis.

Help Implement and Run a Safe Drinking Water in Tupakulagudem Village

where the project site is located to facilitate Healthy Water for both Drinking &

Cooking Purposes.

Contribution towards any developmental activity useful for village

development.

B. Economic Activities:

The company will give preference to the local people for employment.

The company will be giving contract works like civil, machine repair,

transportation, canteen, etc. to the local people / parties.

The proposed project will create jobs for at least 50 persons.



10.26 WASTE MINIMIZATION / RESOURCE CONSERVATION

5 R Concept (Recycle / Refuse / Reduce / Reuse / Reform)

In our company, the 5R, representing five environment-conscious words starting with

the letter R, has been adopted as a keyword for environmental activities. The five

environment-conscious words include the three R words of the 3R, the keyword for

establishing a recycling-oriented society, and two additional words that are "Refuse"

and "Reform".

Refuse: Avoid purchase of environmentally burdensome materials

whenever possible

Reduce: Reduce waste material generation by conservation of input materials

Reuse: Reuse waste material by processing to produce by products

Reform: Reuse materials in a different form

Recycle: Recover and Recycle the resources like water.

We will achieve the above concept; all efforts will be made by the industry to carryout

R&D on the isolated by-products / wastes

FIGURE- 10.9: 5 R CONCEPTS

The units shall also implement the waste minimization circle including:

Good House Keeping: Proper housekeeping practices make the system easier and less costly.

Roof water harvesting system shall be adopted to reduce the fresh water

requirement.

Cleaner production technology may be adopted for the resource conservation and pollution control.



10.27 CREP ACTION POINTS FOR PHARMACEUTICAL INDUSTRIES S. No GUIDELINES COMPLIANCES

Segregation of waste streams: Waste streams should be segregated into high COD waste ,toxic waste, low COD waste, inorganic waste etc, for the purpose of providing appropriate treatment

Effluent is segregated in HTDS from process and washings, HTDS from scrubbers & utilities streams and sent to ETP- ZLD accordingly. HTDS effluent is sent to steam stripper first to remove low boiling solvents which is further distilled and sent to authorized cement industries for incineration Steam stripper outlet is sent to MEE and condensate is sent to ETP for further treatment and reuse Segregation of HCOD is from process and LCOD is from Non process.

Detoxification and treatment of high COD waste streams High COD streams will be detoxified and treated in ETP.

High COD waste streams are collected along with the HTDS/HCOD stream and sent to steam stripper to separate HCOD effluent. This HCOD effluent is distilled out to remove moisture and moisture free HCOD stream mainly consists of unrecoverable mixed solvents which will be sent to Authorized cement industries as per CPCB guidelines

3

Hazardous solid waste Management Proper facilities should be provided for handling and storage of hazardous waste. For final disposal of hazardous waste, recycling and reuse should be given priority, either within the premises or outside with proper manifest system. In case of incinerable waste, property designed incinerator should be installed within the premises or outside as a common facility.

Covered raised platform with leachate collection pit will be provided for storage of Hazardous waste. Hazardous waste will be segregated as organic waste, inorganic waste and recyclable waste like waste / used oils etc. Organic waste like process residue, spent carbon, distillation residue, spent mixed unrecoverable solvents etc., will be stored and sent to SPCB Authorized cement industries. Inorganic waste like process inorganic waste, ETP sludge, evaporation salts etc., will be sent to HWMP- TSDF for landfill. Industry will obtain membership after



obtaining CFE and enter into agreement with TSDF after obtaining CFO since facility will require sample for analysis for acceptance by HWMP - TSDF

4

Minimum scale of production to afford cost of pollution control For new industries which are not connected with CETP & TSDF and which do not have the economics to install treatment facilities may not be considered for granting consent to establishment. Industry association shall submit proposal to SPCB/CPCB

Membership with CETP is not required for this unit as industry is proposing for ETP – ZLD system for reusing the treated water into cooling towers. Organic hazardous waste is proposing to send to authorized cement industries for using as alternate fuel. Industry is proposing to take membership with HWMP- TSDF for sending the inorganic waste for landfill. Project proponent is proposing new Bulk Drug industry with an overall investment on pollution control equipment of Rs. 5.0 Lakhs and recurring cost Will be about Rs.1.0 Lakh per annum.

5

Long term strategies for reduction in waste Consent for establishment and consent for operation under the Water Act will be based on pollution load and concentration of pollutants. Each industry will submit pollution load, concentration of final discharge along with water balance to SPCB/CPCB for formulation of strategy

Pollution load, concentration of pollutants is given in the chapter 2 of this EIA report. All the provisional control methods under R&D to reduce the minimization of Air & water pollution load

6

Control of air pollution Industry will take up in priority the control of hazardous air pollutants (such as Acetonitrile, methanol,).

Solvents will be stored under controlled conditions in tanks and drums. Handling of these solvents will be made through dedicated pipelines from storage tanks to day tanks and as per SOP for the remaining Solvent recovery with fractional distillation system with two stage condensers for recovering the solvent to the maximum extent possible will be obtained.

7

Self – regulation by Industry through regular monitoring and environmental auditing Industries on their will carry out monitoring environmental parameters,

Detailed Environmental monitoring program has been developed for the proposed project and incorporated in this chapter.



audit it at regular interval and submit the same to SPCB.

8

Organizational restructuring and accreditation of Environmental Manager of Industry (a) Environment management cell will be created for each industry reporting to CEO directly- Implementation by June2003. (b) There should be a certification system for the environmental managers at individual level and common facility level.

The project proponent will create Environment, Health and Safety [EHS] cell which will be headed by PG with 12 years experience in similar industry. Training will be provided to all the newly recruited employees including regular training /mock drills.

9

Optimizing the inventory of hazardous chemicals The Information shall be submitted to SPCB regularly along with rational- action plan

Proposed inventory based on the production quantities. Research for alternative processes for production will be carried out regularly and progress if any will be notified to SPCB/MoEF&CC. Maximum storage will be about 10 days other than some liquid raw materials which will be stored maximum of 10KL.

10.28 CONCLUSION

Proposed Project Management having a broad view to develop his state and

industrially backward district, correctly decided to setup the manufacturing unit. The

infrastructure like water and regular supply of power, availability of adequate skilled,

semi-skilled man power at reasonable salaries and wages, local amenities at

reasonable cost, has encouraged the technocrat.

Importantly, the helping hand extended to the most experienced and reputed person

in the bulk manufacturing industrial belt, by the state Government in meeting the

needs of the aspirant.

The likely adverse effects due to the operations of the proposed unit are very

marginal and negligible. More over the residential area is far away. However, the

effective implementation of the recommended Environment Management Plan and

Monitoring Program, all the negative effects on the environment will be mitigated. As

the industry has to obtain Environment Clearance prior to operation, has submitted

this application.

SUMMARY & CONCLUSION [SUMMARY OF EIA REPORT]

CHAPTER -XI


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter -XI Page 1

CHAPTER – XI

PROJECT SUMMARY & CONCLUSIONS Vensar Laboratories Pvt Ltd is a proposed Bulk drugs & Intermediate manufacturing

unit with the production capacity of 10.00 MT/Month respectively.

11.1 SALIENT FEATURES OF THE PROJECT S. No Contents Details

1 Name of the Project: Vensar Laboratories Pvt Ltd Survey Nos: 32, Tupakulagudem (V) Tallapudi (M), West Godavari (Dist.), Andhra Pradesh.

2 Details of Applicant

P.A. RAMARAJU (Director) E-mail: [email protected] Ramaraju [email protected] Web site: - Landline No: 040-23812956, 040-23075699, 40126589. Mobile No: - 9666233370

3 Status Proposed Bulk Drugs & Intermediate manufacturing unit

4 Type of Land & Status Private land Site area : 7.00 Acres (28328.00SQM)

5 Capital Investment of the Project, Rs. in Crores 6.00 Crores

6 Capital Investment for EMP, Rs. in Lakhs 100.0 Lakhs

7 Recurring cost for EMP, Rs. in Lakhs 19.0 Lakhs

8 Employment opportunity 50 persons

9 Green belt Development It is envisaged to develop greenbelt on all sides of the industry in an area of about 2.45Acres (9914.8SQM)

10

Pollution control

Effluent water disposal

Flue gas emission control

ZLD System Adequate stack height of 32 mts. For wider dispersion of pollutants For SPM control, provided cyclone separator followed by bag filter Two stage scrubbers installed for process gas emissions


Prepared By Rightsource Industrial Solutions Pvt. Ltd. Chapter -XI Page 2

Process gas emission control

Hazardous waste

management

Vent condensers to the storage tanks and reactors Solvents and chemicals are handling in closed system All the hazardous waste will be collected, stored, handled, transported and disposed to TSDF as per the Hazardous Waste (Management, Handling & Tran boundary Movement) Rules, 1989 as Amended in 2008, same as current practice.

11 Annual Expenditure for CSR activities Rs. 30 Lakhs for five years

11.2 CONCLUSIONS

It can be concluded on a positive note that after the implementation of the proposed project,

mitigation measures and environmental management plans, the project activities during the

construction and operation phase would have manageable & largely have reversible impacts on

the environment and on balance the project would be beneficial to surrounding communities and

the region.

DISCLOSURE OF CONSULTANTS ENGAGED

CHAPTER -XII

ENCLOSURES

CONSOLIDATED STATEMENT – POLLUTION LOAD DETAILS

NEWS PAPER ADVATISEMENT [PUBLIC HEARING]

MINUTES OF THE MEETING

[PUBLIC HEARING]

SPCB PRESENT STASTUS

CERTIFICATE SUBMISSION

ACKNOWLEDGEMENT

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