Prefeasibility of BSG -...

Pre-Feasibility Report BSG Chemicals and Pharmaceuticals Pvt. Ltd.

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1. Introduction

M/s. BSG Chemicals and Pharmaceuticals private limited is located in Sy.

Nos. 3, 4, 5, 9 to 14 Donivanilakshmipuram (V), Nakkapalli (M),

Visakhapatnam District in Andhra pradesh. The unit acquired 70.4 Acres

of land in the following survey numbers.

S.No Survey No. Area in acres

1 Survey no.5 6.06

2 Survey no.4 2.90

3 Survey no.4 7.00

4 Survey no.5 3.00

5 Survey no.11/2 1.55

6 Survey no.12 3.48

7 Survey no.3/1 3.93

8 Survey no.3/2 1.24

9 Survey no.11/1 4.07

10 Survey no.3/1 0.71

11 Survey no.3/2 0.28

12 Survey no.3/4 1.37

13 Survey no.3/5 1.76

14 Survey no.9/2 1.04

15 Survey no.10/1 0.71

16 Survey no.10/2 0.33

17 Survey no.10/3 0.41

18 Survey no.11/1 0.73

19 Survey no.11/2 0.41

20 Survey no.12 0.64

21 Survey no.13/1 0.38

22 Survey no.13/2 0.55

23 Survey no.14/2 0.71

24 Survey no.9/2 5.00

25 Survey no.9/2 2.30

26 Survey no.10/1 2.70

27 Survey no.13/1 1.96

28 Survey no.13/2 2.63

29 Survey no.14/2 3.95

30 Survey no.5 3.0

31 Survey no.11/2 0.57

32 Survey no.10/2 1.63

33 Survey no.10/1 1.25

33 Survey no.10/3 2.15

Total 70.4


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It is proposed to establish a medium scale unit with an investment of Rs.

15.6 Crores. It is proposed to establish Zeroliquid Discharge plant with

adequate facilities for solvent handling and hazardous waste storage

facilities.

Copy of sale deed is enclosed at Annexure I.

Copy of land conversion documents are enclosed as Annexure II

As the site is situated outside the industrial area, this comes under

category A project under EIA notification 2006


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2. About the Project

The salient features of the project are described in table below

TABLE 1.0

Salient Features of the Project

Location Sy. No. 3,4,5,9 to 14

Donivanilakshmipuram (V), Nakkapalli (M), Visakhapatnam (D) Andhra pradesh

Longitude and latitude

17o 20’43.2’’ N & 82o 39’22.9’’ E 17o 20’42.4’’ N & 82o 39’31.6’’ E 17o 20’52.0’’ N & 82o 39’35.0’’ E 17o 20’52.6’’ N & 82o 39’29.4’’ E 17o 20’56.2’’ N & 82o 39’29.8’’ E 17o 20’59.3’’ N & 82o 39’11.0’’ E 17o 20’48.6’’ N & 82o 39’06.8’’ E

17o 20’42.4’’ N & 82o 39’22.7’’ E

Product category 5(f), Drugs & Drug Intermediates

Project category as per EIA notification

Category A

Proposed Activity Drugs , Drug intermediates and Chemicals-50.0TPM

Total investment on the plant Rs. 15.6 Crores

Total Investment on Environmental Infrastructure

Rs.2.5 Crores

Total area of the plant 70.4 Acres

Total area of green belt 28.16 Acres

Water requirement Total water requirement- 121.5 KLD Freshwater Requirement-81.5 KLD Recycled water is 40.0 KLD

Source of water

Borewell

Nearest habitation and

distance from the site

Donivani lakshmipuram (V) 0.9 Km(SE)

Nearest surface water bodies Rain fed water tank at a distance of 0.5 Km in SE direction from the site

Nearest reserve forest Vempadu reserve forest is at a distance of 0.4 Km(W)

Environmentally sensitive

areas within 10 km radius

None

Any national parks, wild life

sanctuaries within 10 km radius

None

Nearest air port and distance Visakhapatnam Airport-73 Km

Nearest railway station and distance

Tuni at a distance of 12.1 Km from the plant

Distance from National

highway

NH5 is at a distance of 5.16 Km


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i) About the Group & Promoters

The management at BSG Chemicals and pharmaceuticals private limited

consists of highly qualified and richly experienced persons. The company

is headed by B. Sarath Gopal Managing Director.

3. Project Description

3.1 Proposed Products & Production Capacity

M/S BSG Chemicals and pharmaceuticals private limited proposed to

establish manufacturing unit to manufacture Bulk Drugs, Drug

Intermediates and Organic chemicals. Also it is proposed to establish R&D

and Pilot Plant to manufacture customer synthesis products and R&D

Products to a tune of 1.2 TPA. Below Table provides list of proposed

products & capacity.

TABLE 2.0

LIST OF PROPOSED PRODUCTS

S.No Product Name

Production

Capacity TPM

Product Description

Drug/Intermediate/

Multipurpose chemicals

Bulk Drugs

1 Losatran potassium 2.4 Drug

3 Fluconozole 3.0 Drug

4 Ketorolactromethamine 3.0 Drug

5 Ondansetron Hydrochloride dihydrate

3.0 Drug

6 Atrovastatin Calcium 4.5 Drug

7 Olanzapine 2.4 Drug

8 Linezolide 1.5 Drug

9 Sumatriptan 0.6 Drug

10 QuetiapineFumarate 3.0 Drug

11 DronedroneHCL 3.0 Drug

Total Bulk Drugs 26.4 TPM

Drug Intermediates

1 CIS (+) Hydroxylactum 10.0 Drug Intermediate

2 Pramipexole Hydro chloride Intermediate

4.5 Drug Intermediate


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Total Drug

Intermediates 14.5 TPM

Multipurpose Chemicals

1 Sodium Methoxide 9.0 Chemical

Total Multi-Purpose

Chemicals 9.0 TPM

Custom Synthesis products & R&D products

1 Drugs and Intermediates in pilot scale

0.1 TPM

Total 50.0 TPM

3.2 Manufacturing Process

Brief process description and process flow charts are given at Annexure

III

3.3 Raw Materials

List of raw material product wise is given at Annexure IV

3.4 Water Requirement

The water requirement will be met from Borewell. The requirement for

water in this unit is for process and domestic purposes. The water balance

for daily consumption is presented below.

TABLE 3.0

Water Balance–Proposed

S.No Stream Water

requirement KLD

Wastewater Generation

KLD

Method of Treatment and

Disposal

1 Process 33.5 36.6

MEE followed by

ATFD. (Condensate to ETP & RO)

2 Washings 5.0 5.0

MEE followed by

ATFD. (Condensate

to ETP & RO)

3 Scrubbers 5.0 5.0

MEE followed by

ATFD. (Condensate

to ETP & RO)


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4 QC, R&D and Pilot

Plant

2.0 2.0 MEE followed by ATFD. (Condensate

to ETP & RO)

5 Boiler

make up 25.0 2.5

ETP & RO (RO Reject

to MEE)

6 Cooling Towers

make up 10.0 1.0

ETP & RO (RO Reject

to MEE)

7

RO back

washes and rejects

10.0 10.0 ETP & RO (RO Reject to MEE)

8 DM/Softner Plant back

washes

1.0 1.0 ETP & RO (RO Reject to MEE)

9 Domestic 10.0 8.0 ETP & RO (RO Reject to MEE)

10 Gardening 20.0 --

Total 121.5 71.1

3.5 Wastes generation and control systems

3.5.1 Liquid Effluents

As detailed in table 4.0 waste water generation would be 71.1 KLD. It is

proposed to segregate effluents into high COD and High TDS stream and

Low COD and Low TDS streams

High TDS and High COD stream would be treated in stripper followed by

MEE and ATFD. The resultant sludge would be disposed to TSDF,

Hyderabad. The Low TDS stream would be treated along with MEE/ATFD

condensates in biological ETP followed by RO. The RO rejects would be fed

back to MEE. The Permeate from RO would be used for cooling tower

make up. Thus the treatment system proposed is based on “Zero Liquid

Discharge” (ZLD) Concept

The schematic diagrams of ETP proposed are given in Figure 1.1 and

Figure 1.2 below


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Fig 1.1 Schematic treatment scheme of high TDS effluents

Effluent from

Process and

Reactor and RO rejects

Floor washings

Sludge to TSDF

Condensate to

Biological

Treatment

Condensate to Biological Treatment

Sludge to TSDF

Equalization

Tank

MEE

ATFD

Neutralization

Tank

Setting

Tank


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Fig 1.2 Low TDS Effluent Treatment System

Domestic effluent

Effluents from utilities MEE condensate

Sludge to TSDF

Permeate for re-use

Rejects to MEE

Screen

Chamber

Sludge Holding

Tank

Equalization

Tank

Neutralization

Tank

Clarifier

2

Holding

Tank

Filter Press

Sludge Cake

Aeration

Tank1

Clarifier

1

Sand

filter

Carbon

Filter

Ultra

filtration RO

Screen

Chamber


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3.6.2 Solid wastes management

Hazardous and non - hazardous wastes generated from the proposed

project are detailed below. Mode of disposal are also identified and listed.

Adequate storage of hazardous waste is ensured at the site

TABLE 4.0

Solid Wastes and Disposal

S.No

Description Quantity in TPM

Remarks

Hazardous waste

1 MEE salts 43.2 Sent to TSDF Dundigal

2 ETP Sludge 6.0

3 Process/ organic

Residue

69.6 Sent to TSDF/ Cement

plant for Co-

incineration in rotary kilns

4 Inorganic salt from process

0.39 Sent to TSDF Dundigal

5 Spent Carbon 3.63 Sent to TSDF Dundigal

TOTAL 122.82

Non- Hazardous waste with recycling option

6 Ash from boilers 171.0 Sold to brick

manufacturers

7 Waste /Used Oil 100 LPM Authorized Recyclers/

Re-processors

8 Mixed spent solvents 15.0 TPD Authorized Recyclers

9 Used batteries 5 Nos/

Annum

Sent to Authorized

Recyclers

10 container & container liners of hazardous

waste & chemicals

1000 Nos/month

After detoxification, disposed to outside

agencies


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TSDF Parawada facility in Visakhapatnam District is created for catering

the industries in this area. Transport of Hazardous wastes to TSDF is done

by Ramky. In case other hazardous wastes, authorized recyclers will

transport the wastes

4. Site Analysis

4.1 Plant Location

M/S BSG Chemicals and Pharmaceuticals is located at Sy. No. 3,4,5,9 to

14 Donivanilakshmipuram (V), Nakkapalli (M), Visakhapatnam District in

Andhra pradesh. The land area of the plant is 70.4 acres. The nearest

habitation from the site is Donivanilakshmipuram(V) at a distance of 0.9

Km. The nearest railway station is located at Tuni at a distance of 12.1

Km from the site.

There are few rainfed irrigation tanks within 10 KM radius of the site.

There are no ecologically sensitive areas like national parks, sanctuaries

within 10 km radius of the site. Following are the surroundings of the site

North – Road

South – Road & Mango plantations

East – Mango Plantations

West – Government land

There is only 1 reserve forest in the study area.

Table 5.0

Reserve Forests in the study area

S.No Reserve Forest Distance from the site

Direction from the site

1 Vempadu R.F 0.4 West

Topo graphic features of the site and 10 KM study area & Base map is

given at Fig 1.3.

Photographs of Current condition of the site is given at Fig. 1.4

Site lay out map is given at Fig 1.5.


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Fig 1.3

Topo map of the 10 KM study area


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Base Map of the Study Area


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Fig 1.4

Photographs of current condition of the site


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Fig 1.5

Site lay out plan


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5.0 Planning in Brief

The project is envisaged to be completed by December 2017 and the

production shall be initiated thereon. Consultants are identified for

preparing the detailed project report.

6. Resource requirements

6.1 Power Requirement and Supply/Source

The total power requirement is 1250 KW. It shall be sourced from

APCPDCL

It is proposed to establish D.G sets as alternative to Power failure.

6.2 Production facilities, Utilities and effluent handling facilities

TABLE 6.0

Utilities/ETP –Proposed

S.NO Details Capacity/

No Proposed

Production facilities

1 Production Blocks Nos 2

2 Pharma Blocks Nos 1

3 Clean rooms Nos 1

4 Boiler (coal Fired) TPH 1 x6 & 1x4*

6 Thermic fluid heater Lakh/ Kcal 2.0

7 DG sets KVA 1 x 750 & 1 x

380

8 Cooling tower TR 2000

9 Nitrogen plant M3/Hr 5

10 Chilling plants TR 200 & 60

11 Softner/DM plant M3/hour 10

12 Fresh water RO Plant M3/hour 10

Effluent handling & treatment facilities

13 collection tanks-Storage KL 100

14 Neutralisation tanks KL 100

15 Stripper, MEE, ATFD KLD 50

16 RO & Biological treatment

KLD 100


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* 4 TPH boiler shall be kept as standby

* DG Sets are used only during load shutdown by APCPDCL

6.3 Land Requirement

The unit currently has 70.4 acres of land and out of which 28.16 acres of

green belt is developed. The land requirement for proposed activities will

be met from existing open area. Below table provides the land statement.

Detailed site lay out plan outlining proposed activities is given at Figure

1.5

Table 7.0

Land Statement

S.NO Purpose Units Extent

1 Built up area Sq.M 33878.61

2 Roads Sq.M 28497.72

3 Green belt Sq.M 113990.08

4 Open area Sq.M 108610.80

Total Sq.M 284977.20

7.0 Air Pollution

The Sources of air emissions from the plant are 6.0 TPH coal fired boiler &

4.0 TPH coal fired Boiler.

The process emissions contain HBr, CO2, O2, N2 and SO2. HBr emissions

are4 scrubbed in two stage scrubber, SO2 emissions are scrubbed with

caustic lye and scrubbed waste is send to MEE. The other gases expected

in the process are N2, O2 and CO2 which are let out into the atmosphere.

Below Table gives proposed emission sources from the plant.


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Table 8.0

Emission Source –Proposed

S.NO Source Capacity

Fuel Anticipated emissions

Control system

1 Boiler 6 & 4 TPH

Coal SPM, SO2, NOx

Bag Filters

2 DG sets 1 X 750 & 1 X

380 KVA

Diesel -- Acoustic enclosure

3 Thermic fluid heaters 2x105 k.cal/hr

Diesel -- Adequate stack

4 Process emissions -- -- HBr, SO2, Scrubber

8. Bulk Chemicals Storage

Following bulk chemical storage facilities are proposed.

Table No 9.0

Storage facilities of bulk chemicals

Sr

No

Capacity

(KL) Name of the solvent MOC

1 20 Acetone SS

2 20 IPA SS

3 20 Toluene SS

4 20 Ethylacetate SS

5 20 Toluene SS

6 20 Diesel SS


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9.0 Project Financial

The estimated cost of the project is approximately 15.6 Crores. Out of

this Rs. 2.5 Crores will be for effluents treatment facilities and rest for

other utilities

Project cost

Rs. In

lakhs

Land 180

Plant & machinery 800

Civil & structural

Roads/Drains/Dykes etc 200

Total 1180

Pipe lines & insulation 20% on plant & machinery 160

Electricals & instrumentation 10% on plant & machinery 80

Erection & commissioning & painting

10% on plant &

machinery and structures 80

Safety & Environment 25

Furniture, fixtures, computers,

lighting etc 15

Contingencies & pre-operative expenses 20

Project cost 1560

Say Rs. 15.6 Crores

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