THE PROPOSED EXPANSION OF API BULK DRUGS...
Transcript of THE PROPOSED EXPANSION OF API BULK DRUGS...
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
FOR
THE PROPOSED EXPANSION OF API
BULK DRUGS MANUFACTURING UNIT
Category: 5(f)
OF
AMOLI ORGANICS PVT. LIMITED.
Located at:
Plot No. 322/4, 40 shed Area,
GIDC Notified Industrial Area, Vapi, Ta: Pardi, Dist- Valsad
396195. (Gujarat).
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: I MANUFACTURING :API BULK DRUGS
CONTENTS
1 EXECUTIVE SUMMARY .............................................................................................. 1
1.1 NAME & LOCATION: ............................................................................................... 1
1.2 PROJECT PROPONENT ............................................................................................ 1
1.3 PROJECT DESCRIPTION .......................................................................................... 2
1.4 ENVIRONMENT ........................................................................................................ 5
2 INTRODUCTION OF THE PROJECT ......................................................................... 8
2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ............................. 8
2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT ........................................... 10
2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR
REGION ............................................................................................................................. 10
2.4 DEMAND SUPPLY GAP ........................................................................................... 10
2.5 IMPORT VS INDEGINEOUS PRODUCTION ........................................................... 10
2.6 EXPORT POSSIBILITY ............................................................................................... 11
2.7 DOMESTIC/EXPORT MARKETS .............................................................................. 11
2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE PROJECT 11
3 PROJECT DESCRIPTION............................................................................................. 12
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND INTERDEPENDENT
PROJECT, IF ANY .............................................................................................................. 12
3.2 LOCATION WITH CO-ORDINATES ........................................................................ 12
3.3 DETAILS OF ALTERNATE SITES CONSIDERED ...................................................... 12
3.4 SIZE OR MAGNITUDE OF THE OPERATIONS ....................................................... 12
3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS .............................................. 12
3.6 RAW MATERIALS & FINAL PRODUCTS ................................................................ 12
3.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED IN THE
PROJECT ............................................................................................................................ 18
3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER REQUIREMENT AND
SOURCE SHOULD BE GIVEN .......................................................................................... 19
3.8.1 Water ................................................................................................................. 19
3.8.2 Power ................................................................................................................. 21
3.9 QUANTITY OF WASTES TO BE GENERATED AND SCHEME FOR THEIR
MANAGEMENT/DISPOSAL ............................................................................................. 21
3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING WHICH GIVE
INFORMATION OF EIA PURPOSE .................................................................................. 21
4 SITE ANALYSIS ............................................................................................................ 22
4.1 CONNECTIVITY ........................................................................................................ 22
4.2 LAND FORM, LAND USE AND LAND OWNERSHIP............................................. 22
4.3 TOPOGRAPHY (ALONG WITH MAP) ..................................................................... 22
4.4 EXISTING LAND USE PATTERN .............................................................................. 22
4.5 EXISTING INFRASTRUCTURE .................................................................................. 22
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: II MANUFACTURING :API BULK DRUGS
4.6 SOIL CLASSIFICATION ............................................................................................. 22
4.7 CLIMATIC DATA FROM SECONDARY SOURCES ................................................. 22
4.8 SOCIAL INFRASTRUCTURE ..................................................................................... 23
5 PLANNING BRIEF ........................................................................................................ 25
5.1 PLANNING CONCEPT.............................................................................................. 25
5.2 POPULATION PROJECTION .................................................................................... 25
5.3 LANDUSE PLANNING .............................................................................................. 25
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND................................................... 26
5.5 AMENITIES/ FACILITIES ........................................................................................... 26
6 PROPOSED INFRASTRUCTURE ................................................................................ 27
6.1 INDUSTRIAL AREA (PROCESSING AREA). ............................................................. 27
6.2 RESIDENTIAL AREA .................................................................................................. 27
6.3 GREEN BELT .............................................................................................................. 27
6.4 SOCIAL INFRASTRUCTURE ..................................................................................... 27
6.5 CONNECTIVITY ........................................................................................................ 27
6.6 DRINKING WATER MANAGEMENT ....................................................................... 27
6.7 SEWAGE SYSTEM ..................................................................................................... 27
6.8 INDUSTRIAL WASTE MANAGEMENT .................................................................... 27
6.9 POWER REQUIREMENT & SUPPLY/ SOURCE ...................................................... 29
7 REHABLITATION & RESETTLEMENT (R & R) PLAN ........................................... 30
7.1 POLICY TO BE ADAPTED (CENTRAL /STATE) IN RESPECT OF THE PROJECT
AFFECTED PERSONS INCLUDING HOME OUTSEE, LAND OUTSEE AND LANDLESS
LABOURERS ...................................................................................................................... 30
8 PROJECT SCHEDULE AND COST ESTIMATE ......................................................... 31
8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF
COMPLETION ................................................................................................................... 31
8.2 ESTIMATES PROJECT COST ALONG WITH ANALYSIS IN TERMS OF
ECONOMIC VIABILITY OF THE PROJECT ...................................................................... 31
9 ANALYSIS OF THE PROPOSAL (FINAL RECOMMENDATIONS) ....................... 33
9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON THE BEFIT
TO THE LOCAL PEOPLE INCLUDING TRIBAL POPULATION, IF ANY, IN THE AREA 33
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: III MANUFACTURING :API BULK DRUGS
LIST OF TABLES
Table 1-1: Details of Finished Products ............................................................................. 2
Table 1-2: Details of Finished Products ............................................................................. 2
Table 1-3: Details of Resource Requirement ..................................................................... 3
Table 1-4: Details of Raw Material Consumption after proposed Expasnion ............... 4
Table 1-5: Details of Hazardous waste and its Management ......................................... 6
Table 3-1: Details of Product Transportation .................................................................. 12
Table 3-2: Details of Raw Material Transportation ......................................................... 13
Table 3-3: Safe Storage and Handling of Hazardous Chemicals .................................. 15
Table 3-4: Details of Product Wise Solvent Consumption ............................................ 18
Table 3-5: Details of Water Consumption ....................................................................... 19
Table 3-6: Energy Requirements and Its Source ............................................................. 21
Table 3-7: Power Requirements and Its Source .............................................................. 21
Table 4-1: Rainfall projection for Project site and Gujarat for 2011 (June-Oct.) ........ 23
Table 5-1: Area Statemnet of ecisting and Proposed Expansion ................................. 25
Table 6-1: Solid/Hazardous Waste Management .......................................................... 28
Table 8-1: Capital Cost Projection .................................................................................... 31
Table 8-2: Project Viability ................................................................................................. 32
Table 8-3: Recurring/operating Cost Per Annum ........................................................... 32
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: IV MANUFACTURING :API BULK DRUGS
LIST OF FIGURES
Figure 3-1: Water Balance Diagram of Existing Scenario .............................................. 20
Figure 3-2: Water Balance Diagram after Proposed Expansion ................................... 20
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: V MANUFACTURING :API BULK DRUGS
LIST OF MAPS
Map 5-1: Site Layout Map with Green Belt Development Planning ............................ 26
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: VI MANUFACTURING :API BULK DRUGS
LIST OF ANNEXURES
Annexure 1: Location map showing the Project site and inter-state boundary within
5 kms radius ......................................................................................................................... 35
Annexure 2: Site Layout Plan ............................................................................................. 36
Annexure 3: Manufacturing Process with Chemical Reactions and Mass Balance .... 37
Annexure 4: Water Requirement Letter from GIDC ....................................................... 49
Annexure 5: Quantity of Waste Water (liquid waste) Generated and its Management ............................................................................................................................................... 50
Annexure 6: Membership Certificate of CETP, Vapi for Existing and Additional
Effluent Load ........................................................................................................................ 55
Annexure 7: Toposheet Map of Vapi Region .................................................................. 60
Annexure 8: Copy of Plot Allotment Letter issued by GIDC ......................................... 61
Annexure 9: Letter Regarding the Unit is Located In Notified Industrial Area ........... 62
Annexure 10: A Schematic Representation of the Feasibility Drawing ....................... 64
Annexure 11: Details of Air Pollution & Its Control Measures at Existing & After
Proposed Expansion ........................................................................................................... 65
Annexure 12: Copy of CCA of Existing Plant ................................................................... 70
Annexure 13: Copy of Environmental Clearance dated 23/10/2003 ........................... 73
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 1 MANUFACTURING :API BULK DRUGS
1 EXECUTIVE SUMMARY
1.1 NAME & LOCATION:
Name of the Project : M/s Amoli Organics Pvt. Limited
Location : Plot No: 322/4, 40 Shed Area,
G.I.D.C, VAPI. Ta: Pardi, Pin Code: 396195
Dist. - Valsad (Gujarat)
Project
Amoli Organics Pvt Limited is located in GIDC notified industrial area, falling under
medium Scale category manufacturing products as mentioned under which the company
had obtained Consent To Establish and Consent to Operate from Gujarat pollution Control
Board.
The company proposes to enhance the capacity of products under the category “API Bulk
Drugs”.
Existing project cost is Rs. 3022.21 Lakh. Proposed expansion Project Cost: Rs.1005 lakh.
Total project cost after proposed expansion will be Rs. 4027.21 Lakh.
Applicability of EIA notification – 2006
Category as per the amended EIA notification-2006: as existing and proposed
expansion products (i.e. API Bulk Drugs) are covered under the Category-5(f).
Hence, Environmental clearance is required.
As per the EIA Notification the proposed expansion project is covered under
category A due to applicability of General Condition (GC), the same is applied to
MoEF for permission.
Submission for obtaining EC under provision of EIA notification 14 September
2006 as amended till date.
1.2 PROJECT PROPONENT
M/S Amoli Organics Pvt. Limited has started manufacturing plant at Vapi in year
1992 for the manufacture of Bulk Drugs & Intermediates. Amoli Group of
Companies founded by Mr. Umed Doshi.
The unit is operated by technocrats having more than 32 years of experience in
manufacturing and marketing of various API Bulk drugs worldwide. The Company
is WHO GMP, EDQM, EU-GMP standards, ISO certified & USFDA.
The Company is professionally managed with its whole time directors
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 2 MANUFACTURING :API BULK DRUGS
1.3 PROJECT DESCRIPTION
List of Existing and Proposed Products
Table 1-1: Details of Existing and Proposed Products
S. No. Product Capacity, TPM
Existing Proposed Total after expansion
1 Diclofenac Sodium & its Salts
(Diclofenac potassium,
Diclofenac diethyl amine,
Diclofenc free acid, Diclofenac
Resinate, Diclofenac Deonal,
Diclofenac Appolomine)
20.0 245 265
2 Aceclofenac 0.5 49.5 50
3 Norethisterone Acetate 0.25 -0.25 0
4 Clotrimazole 1.0 9 10
5 Oxcarbazepine 5.0 -5.0 0
6 Carbamazepine 1.0 -1.0 0
7 Di Hydralazene Sulphate 1.0 1.5 2.5
8 Sildenafil Citrate 0.5 -0.5 0
9 Pioglitazole 0.5 -0.5 0
10 Momiflumate 1.0 -1.0 0
11 Celecoxib 0.5 -0.5 0
12 Cetrizene Dihydrocloride 0.1 -0.1 0
13 Sertaline Huydrochloride 0.5 -0.5 0
14 Noscapine Resine Complex 0.05 -0.05 0
15 Bifonazole 0.5 4.5 5
16 Nitroxaline 0.05 -0.05 0
17 Formasulphathiazole 1.0 -1.0 0
18 Mentronidazole Bebzoate 1.0 -1.0 0
19 Ascorbic Acid 10.0 -10.0 0
20 Rofecoxib 0.20 -0.2 0
21 2 Chloro Ethyl Phenyl Ether 0.1 -0.1 0
22 Venlafaxine Hydrochloride 0.5 -0.5 0
23 Fexofenadine Hydrochloride 0.5 -0.5 0
24 Catalpidogrel Hydrogensulphate 0.5 -0.5 0
25 Citaiopram Hydrobromide 0.5 -0.5 0
26 Pyridoxine Acetonide Hysro
Chloride 0 2.5 2.5
Total 46.75 288.25 335.0
List of Products after Proposed Expansion
Table 1-2: Details of Production after Expansion
S. No. Product Capacity, TPM
1 Diclofenac Sodium & its Salts (Diclofenac potassium,
Diclofenac diethyl amine, Diclofenc free acid, Diclofenac
265.0
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 3 MANUFACTURING :API BULK DRUGS
S. No. Product Capacity, TPM
Resinate, Diclofenac Deonal, Diclofenac Appolomine)
2 Aceclofenac 50.0
3 Clotrimazole 10.0
4 Di Hydralazene Sulphate 2.5
5 Bifonazole 5.0
6 Pyridoxine Acetonide Hydro Chloride 2.5
Total 335
Manufacturing process is attached as Annexure 3
Resource Requirement:
Table 1-3: Details of Resource Requirement
Components Existing Proposed
Total After
Proposed
expansion
Resources availability
Power, KVA 650 950 1600
Will be sourced from
Dakshin Gujarat Vij Co.
Ltd
Fresh Water, kl/day 150 220 370 Will be sourced from
GIDC water supply dept.
Coal for Boiler : I
(3000 kgs/hr), kgs/hr 583 0 583
Will be sourced from
local dealer
Furnace oil for Boiler: II
(3000 kgs/hr), kgs/hr 29 0 29
Is sourced from local
dealer
Furnace for Thermopak
(6 lakh k cal), kgs/hr 35 0 35
Is be sourced from local
dealer
Coal for Boiler : III
(8000 kgs/hr), kgs/hr 0 972 972
Will be sourced from
local dealer
HSD for D G set : I
(500 KVA), kgs/hr 110 0 110
Will be sourced from
local dealer
HSD for D G set :II
(500 KVA), kgs/hr 110 0 110
Will be sourced from
local dealer
HSD for D G set: III
(1250 KVA), kgs/hr 0 220 220
Will be sourced from
local dealer
Cooling Tower, TR 500 700 1200 In-house
Chilling plant, TR 250 200 450 In-house
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 4 MANUFACTURING :API BULK DRUGS
Raw material Consumption after Proposed Expansion
Table 1-4: Details of Raw Material Consumption after proposed Expasnion
S. No. Raw Materials
Quantity, MT
Per Tone Per Month
1.0 For Diclofenac Sodium & its Salts
1.1 2,6 Di Chloro Phenol 0.51 135.15
1.2 Potassium Carbonate 0.22 58.3
1.3 Toluene (Recovered) 0.85 236.25
1.4 Toluene (Fresh) 0.075 10.875
1.5 Aniline 0.29 76.85
1.6 Sodium Methoxide 0.68 180.2
1.7 Chloro Acetyl Chloride 0.36 95.4
1.8 Soda Ash 0.004 1.06
1.9 Sulphuric acid 0.004 1.06
1.10 Aluminum Chloride 0.42 111.3
1.11 Hydro Chloric acid 0.099 26.235
1.12 Caustic soda 0.12 31.8
1.13 Sodium Hydro Sulphide 0.03 7.95
1.14 Charcoal 0.056 14.84
1.15 Iso Propyl Alcohol 0.14 37.1
1.16 EDTA 0.001 0.265
Total 3.859 1022.635
2.0 For Aceclofenac
2.1 Chloro Acetyl chloride 0.72 36
2.2 Tertiary Butanol 0.48 24
2.3 N-N Di methyl aniline (Recovered) 0.70 37.15
2.4 N-N Di Methyl Aniline (fresh) 0.07 1.35
2.5 Sodium bi carbonate 0.01 0.5
2.6 Hydro Chloric acid 0.014 0.7
2.7 Diclofenac sodium 0.89 44.5
2.8 T- Butyl Chloro Acetate 0.539 26.95
2.9 T- Butyl Ammonium Bromide 0.01 0.5
2.10 Formic acid (Fresh) 0.12 6
2.11 Formic acid (recovered) 1.22 61
2.12 Acetone (Recovered) 0.938 46.9
2.13 Acetone (fresh) 0.10 5
2.14 Charcoal 0.009 0.45
2.15 Caustic flakes 0.359 17.95
2.16 Toluene (Recovered) 1.83 93.5
2.17 Toluene (Fresh) 0.096 2.8
Total 8.105 405.25
3.0 For Clotrimazole
3.1 Ortho Chloro Phenyl Di phenyl Chloro methane 0.90 9
3.2 Toluene (recovered) 3.46 34.6
3.3 Toluene (fresh) 0.18 1.8
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 5 MANUFACTURING :API BULK DRUGS
S. No. Raw Materials
Quantity, MT
Per Tone Per Month
3.4 Imidazole 0.27 2.7
3.5 Tri ethyl Amine 0.363 3.63
3.6 Acetone (Recovered) 7.65 76.5
3.7 Acetone (Fresh) 0.807 8.07
3.8 Charcoal 0.03 0.3
Total 13.66 136.6
4.0 For Di Hydralazene Sulphate
4.1 Phthalodinitrile 0.44 1.1
4.2 Hydrazine hydrate 0.911 2.2775
4.3 Acetic acid 0.38 0.95
4.4 Methanol (Recovered) 1.28 3.5
4.5 Methanol (fresh) 0.18 0.146
4.6 Sulphuric acid 0.4 1
4.7 Charcoal 0.05 0.125
Total 3.641 9.0985
5.0 For Bifonazole
5.1 Bifonazole Hydro Chloride 1.11 5.55
5.2 Acetic acid 1.06 5.3
5.3 Acetone (Recovered) 5.66 28.3
5.4 Acetone (Fresh) 0.629 3.15
Total 8.459 42.3
5.5 For Pyridoxine Acetonide Hydro Chloride
6.0 Pyridoxine Hydro Chloride 0.836 2.09
6.1 Acetone (Recovered) 1.16 2.9
6.2 Acetone (fresh) 0.336 0.84
6.3 Diglyme 0.16 0.4
6.4 Phosphorous oxy chloride 0.628 1.57
1.4 ENVIRONMENT
Water and Waste Water Management
Total Raw Water requirement will be 370 KL/day. Supply will be met from GIDC
water supply dept. Copy of GIDC water supply is as attached as Annexure 4.
Total industrial Waste Water Generation will be 264 KL/Day, out of which 18
kl/day of concentrated effluent will be segregated and evaporated in
Mechanical Vapour Re-compressor Evaporator (MVR) and balance 246 Kl/day
of normal effluent and 14.94 kl/day of condensate from MVR will be treated in
proposed modified effluent treatment plant consisting of primary, secondary
and tertiary effluent treatment unit and discharge into underground effluent
drainage line to CETP for further treatment and disposal into tide zone of
River Damanganga to Arabian Sea.
Domestic waste water (17 KL/day) will be passed through Septic Tank and overflow
will be taken to final outlet of ETP.
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 6 MANUFACTURING :API BULK DRUGS
Air Emission and its Control Measures
1. Flue gas emission:
At present, the unit is having one number of 3 TPH of coal fired steam boiler, one
number of 3 TPH oil fired steam boiler and one number of 6 lakh k cal/hr capacity
of oil fired thermopak. Adequate capacity of multi cyclone separator followed by
bag filter and separate 30 meters height of chimney provided. The unit is proposes to
install additional one number of 8 TPH coal fired boiler having ESP and 30 meters
height of chimney will be provided. After proposed expansion, existing oil fired 3
TPH of steam boiler and existing 6 lakh k cal/hr of thermopack will be discontinued.
At present, the unit is having two numbers of 500 KVA of D G set (standby). It will
be used only during power failure. The unit is proposed to install one number of
1250 KVA capacity of D G set (standby). After proposed expansion, existing 500
KVA x 2 numbers of S G sets will be discontinued.
2. Process Gas Emission:
Presently the unit has installed one number of two stage graphite followed by alkali
scrubber and 11 meters height of vent to scrub and recover HCl gas generated from
the process. After proposed expansion, the unit shall install additional one number
of two stage graphite followed by alkali scrubber and 11 meters height of vent to
scrub and recover HCl gas and SO2 generated from the process. (Details of Air
pollution control measures is attached as Annexure 11)
Solid and Hazardous Wastes and its Management
Table 1-5: Details of Soild & Hazardous Waste and its Management
S. No.
Type of Solid &
Hazardous waste
(Hazardous waste
category)
Quantity, TPA
Place of
Storage Disposal
Existing
After
proposed
expansion
Hazardous Waste
1.0 Used oil (5.1) 0.24 0.3 HDPE Drum Sell to registered re-
refiner
2.0 Discarded
containers (33.1) 30.0 50.0 Pallets/drums
Sell to authorized
recycler
3.0 Process Residue &
waste (28.1) 12.0 1200.9 HDPE drums
Sell to actual &
authorized users
4.0 ETP waste, (35.3) 180 4900 HDPE bags Dispose off into
TSDF, Vapi
5.0 Spent Carbon (28.3) 48 192.0 HDPE bags
Sent for co-
processing to RSPL,
Panoli
6.0 Spent solvent (28.6) 20.0 622.764 Storage tank
Recovered in house
and recycled in the
process
7.0
Chemical Sludge
from high COD
stream (35.3)
6.6 0 HDPE drum
Sent to SEPPL,
Kutch for
incineration
8.0 Aluminum Chloride
Soln. (SCH: II, B10) 1500 6264 Storage tank
Sell to actual &
authorized users
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 7 MANUFACTURING :API BULK DRUGS
S. No.
Type of Solid &
Hazardous waste
(Hazardous waste
category)
Quantity, TPA
Place of
Storage Disposal
Existing
After
proposed
expansion
9.0 Used Glass wool (Z-
22) 0.06 0.12 HDPE bags
Dispose off into
TSDF
10. Salt from MEE
(35.3) 0 842 HDPE bags
Dispose off into
TSDF
11.0
Inorganic Acid
(30% HCl) (Sch: II
B 15 0 2922 Storage tank
Sell to actual &
authorized users
12.0 KCl Powder process
(28.1) 0 744 HDPE bags
Sell to actual &
authorized users
13.0 NaCl from process
(28.1) 0 272 HDPE bags
Sell to actual &
authorized users
Solid Non –Hazardous Waste
14.0 Fly Ash 145 (7%) 243 (7%) Silos Send to brick making
industries
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 8 MANUFACTURING :API BULK DRUGS
2 INTRODUCTION OF THE PROJECT
2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT
Project
Name of the project Proponent: Amoli Organics Pvt. Limited
M/S Amoli Organics Pvt. Limited is a medium scale unit & is located in notified
industrial estate, GIDC, Vapi Dist: Valsad, Gujarat having total plot area of 7801m2 & total
investment after proposed expansion will be Rs. 4027.21 Lakhs. The proponent wishes to
enhance the existing production capacity of API Bulk Drugs. The API bulk drugs products
are especially used to relieve pain, swelling (inflammation), and joint stiffness caused
by arthritis.
M/S Amoli Organics Pvt. Limited has started manufacturing plant at Vapi in year 1992
for the manufacture of Bulk Drugs & Intermediates. Amoli Group of Companies founded
by Mr. Umed Doshi.
The group is engaged in the manufacturing and marketing of Active Pharmaceutical
Ingredients & Intermediates. Our products are used to relieve pain, swelling (inflammation),
and joint stiffness caused by arthritis.
The unit is operated by technocrats having more than 32 years of experience in
manufacturing and marketing of various API Bulk drugs worldwide.
The company has established well equipped production plant which is being managed by
dedicated, qualified and skilled persons.
The AOPL is a Leading in manufacturing of Diclofenac Salts. The Company is WHO
GMP, EDQM, EU-GMP standards, ISO certified & USFDA.
Quality Management System ensures strict quality control and Full fledged R&D center.
Pilot plant translates laboratory results into production scale.
Undertake Contract Research and Custom Synthesis and Products with Drug Master Files.
Large clients include many multinational companies.
Dedicated and strong work force with specialized technical experts to meet customer's
specific needs.
A Government of India recognized Export House with exports to more than 88 countries.
Manufacturing plants at this site are well supported by Effluent Treatment Facilities and Air
pollution control system. The management is concerned about Environment and Safety
issues and gives utmost importance to these aspects
The Company was promoted by Mr. Manish Doshi a B Pharm Degree holder. Since
beginning the company has been exporting API bulk drugs in developed marker like USA,
Europe, Pakistan, Italy, Mexico, Korea etc.
Technical knowhow was given to the company by Mr. K L khurana . Company has trained
Plant Managers and Trained ETP operators. Company has also got FDA certification, US
FDA, EDQM, WHO, KFDA certification, to supply product to the European Market.
In view of demand from European and export markets from companies quality product need
for expansion has arisen.
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 9 MANUFACTURING :API BULK DRUGS
The company proposes to expand the capacity of existing product with total capacity of 335
MT per month and process capabilities to manufacture such types of API Bulk Drugs.
The proposed expansion project site lies on 20021’35.42” N Latitude & 72056’06.43” E
Longitude. M/s Amoli Organics Pvt. Limited is located at Plot No: 322/4, 40 shed area,
GIDC Vapi, Dist: Valsad Gujarat. GIDC Vapi is centrally located in both sides of National
Highway No. 8 connecting Mumbai and Ahmedabad and is surrounded by Union territories
of Daman on the western side and Dadra & Nagar Haveli on the eastern side. The western
Railway Main Line passes through the area (Double & Electrified). Vapi is the biggest
railway station in the study area; where, almost all the important mail & express trains stop.
Entire study area is well connected with other major cities of the state and the country.
Beside the rail connectivity, the site is also well connected by road transport. There is a
good network of roads in the area and contributes for the development and economic
growth of the area. The National Highway No. 8 (Surat – Mumbai) is now a six laned,
double tracked, more elevated and Jam free highway, developed by L&T Company. This
highway has given a further boost to the economic growth of this area.
The other major road is state highway No. 185 (Daman – Vapi – Silvasa Road) which is
crosses the NH – 8 in Vapi town. Almost every village in the district is now well connected
to each other by a Pucca road.
About Vapi town: Vapi township has emerged as an Industrial hub on the Gujarat –
Maharashtra border. Administratively, it is a part of Valsad district. After the establishment
of GIDC estate, Vapi has gained a special status on the industrial map of the country mainly
for chemical industrial units. Over the years, it has emerged as a major cosmopolitan
industrial township equipped with hospitals. school, colleges, community centers, temples,
churches, mosques, cinema house, fire stations, blood banks, water filtration plants, police
stations, post offices, banks, telephone exchanges hotels, guesthouses etc. The town has got
a major face-lift after the completion of national highway and other links roads are of good
standard. Mumbai, the economic capital of the country is 180 km from Vapi; whereas, the
state capital “Gandhinagar” is 370 kms. The district Head Quarter – Valsad is 30 km from
Vapi town.
VAPI INDUSTRIAL ESTATE: Vapi Industrial estate came into existence during 1967-
1968. The entire estate, which was developed in phases, is now spread over 1140 hectares
and houses more than 1400 industries, most of which are small-scale industrial units
although some have grown bigger units at later stages. The industrial township is basically a
declared “Chemical Estate” where about 705 of the industrial units are either Chemical or
Chemical related, such as, Dyes and Dyes intermediates, pigments pesticides, fine
chemicals, pharmaceuticals, etc. The remaining 30% comprises of paper mills, packing,
plastics, engineering, textiles, paints, food processing, printing, etc. One of the country’s
largest common effluent treatment plants has been setup in Vapi industrial estate. Being a
major industrial & commercial centre, it caters to other peripheral industrial estates like
Daman, Silvassa, Sarigam, Umbergaon & Dadra and Nagar Haveli, etc.
M/S AMOLI ORGANICS PVT. LIMITED was incorporated in 1992 and is engaged in
the business of manufacturing and marketing API Bulk Drugs. The company has its
corporate office at 407, Dalamal house, Jamnalal bajaj road, Nariman point, Mumbai
400021 and manufacturing unit at Plot No. 322/4, 40 shed area, GIDC, Vapi , Dist: Valsad,
Gujarat.Brief description of nature of the project
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 10 MANUFACTURING :API BULK DRUGS
Project Proponent
The Company was promoted by Mr. Manish Doshi a B.Pharm Degree holder. Since
beginning the company has been exporting Api Bulk drugs in developed countries.
Technical know how was given to the company by Mr. K L Khurana for API Bulk drugs.
Company has trained Plant Managers and Trained ETP engineers and operators.
The Company is professionally managed with its whole time directors as mentioned below.
1. Mr. Manish Doshi
2. Mrs. Vandana Doshi
3. Mr. K L Khurana
4. Mr. Rupesh Kamdar
2.2 BRIEF DESCRIPTION OF NATURE OF THE PROJECT
M/s Amoli Organics Pvt. Limited proposes the expansion of their production capacity at
Plot No. 322/4, 40 shed Area, GIDC, Vapi, Ta: Pardi, Dist: Valsad, Gujarat.
The proposed expansion project involves in the production of “API Bulk Drugs”. As per the
amended EIA notification- 2006, the proposed product is covered under category 5(f)- b
and hence require Prior Environmental Clearance. As proposed expansion project is located
in notified area and project falls under Category B. Due interstate boundary of union
territory of (D N H) within the 5 kms radius (General condition), the project falls under 5(f)
A category as per EIA notification 2006 & amended till date.
For the proposed project, the company intends to procure the latest technology for
manufacturing the products.
2.3 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY
AND OR REGION
The proposed project provides a potential growth opportunity for the already running
business of the company. The company is engaged in the business of manufacturing of API
Bulk Drugs. The project would increase the overall export and also increase the foreign
revenue. Product is now well established and acceptable in the international markets.
Additional capacities of product range required over and above our existing capacities, as
the company expects growth of exports to the extent of 60-70%. Local market is also
showing strong growth potential.
2.4 DEMAND SUPPLY GAP
The product has very high specific demand as API bulk drugs products are especially used
to relieve pain, swelling (inflammation) and joint stiffness caused by arthritis.
2.5 IMPORT VS INDEGINEOUS PRODUCTION
Existing product manufactured in the country will be very much economical compared to
imports of the same and also the export of the same will earn extra revenue generation for
our county
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 11 MANUFACTURING :API BULK DRUGS
2.6 EXPORT POSSIBILITY
Existing product has high export potential. Also this product has very good potential in the
local market.
Additional capacities of product range required over & above the unit’s existing capacities,
as the company expects strong growth of exports to the extent of 60-70%. Local market also
shows strong growth potential.
2.7 DOMESTIC/EXPORT MARKETS
The company’s product is used to relieve pain, swelling (inflammation) and joint
stiffness caused by arthritis. These are having very good demand in domestic as well as
international markets.
2.8 EMPLOYMENT GENERATION (DIRECT AND INDIRECT) DUE TO THE
PROJECT
There will be very good opportunity of employment generation directly and indirectly due
to proposed expansion project. Due to proposed project there will be requirement of
manager, supervisor, operator and semi-skilled workers. For this, the company will employ
about additional 200 people to fulfill its need to handle the plant. (Existing manpower: 100+
additional: 200=total 300).
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 12 MANUFACTURING :API BULK DRUGS
3 PROJECT DESCRIPTION
3.1 TYPE OF PROJECT INCLUDING INTERLINKED AND
INTERDEPENDENT PROJECT, IF ANY
The proposed expansion project is an interdependent project of the company. There is no
interlinked project.
3.2 LOCATION WITH CO-ORDINATES
The map showing general location, specific location and project boundary and project site
lay out is enclosed as Annexure 1. Plant layout is attached as Annexure 2.
3.3 DETAILS OF ALTERNATE SITES CONSIDERED
The proposed activity will be accommodated within the existing factory premises javing
sufficient land located in the notified industrial area having proper industrial
infrastructure so; there is no alternate site consideration. (Plot allotment letter is attached
as Annexure 8)
3.4 SIZE OR MAGNITUDE OF THE OPERATIONS
As per the proposed project cost, the project is covered under medium scale category of
manufacturing industries.
3.5 PROJECT DESCRIPTION WITH PROCESS DETAILS
Detailed project description with process details is enclosed as Annexure 3.
3.6 RAW MATERIALS & FINAL PRODUCTS
Detailed raw material requirement along with estimated quantity, likely source, marketing
of final products, mode of transport of raw materials and finished products &
characteristics of hazardous chemicals are given in following tables:
Table 3-1: Details of Product Transportation
S.
No. Product
Physical
State Dispatch
Means of
Transportation
1.0
Diclofenac Sodium & its
Salts (Diclofenac
potassium, Diclofenac
diethyl amine, Diclofenc
free acid, Diclofenac
Resinate, Diclofenac
Deonal, Diclofenac
Appolomine)
Solid Local/Export Fibre Drum/
Container
2.0 Aceclofenac Solid Local/Export Fibre Drum/
Container
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 13 MANUFACTURING :API BULK DRUGS
S.
No. Product
Physical
State Dispatch
Means of
Transportation
3.0 Clotrimazole Solid Local/Export Fibre Drum/
Container
4.0 Di Hydralazene Sulphate Solid Local/Export Fibre Drum/
Container
5.0 Bifonazole Solid Local/Export Fibre Drum/
Container
6.0 Pyridoxine Acetonide
Hydro Chloride Solid Local/Export
Fibre Drum/
Container
Table 3-2: Details of Raw Material Transportation
S.
No. Substance
Physical
State
Source of
Supply
Means of
Transportation
Distance of
supplier from
project site
(km)
1 2,6 Di Chloro
Phenol Solid Local/Import Drums 3492 km
2 Potassium
Carbonate Solid Local/Import Bags
260 km/8000
km
3 Toluene Liquid Local/Import Tanker 660 km
4 Aniline Liquid Local Tanker 170 km
5 Sodium
Methoxide Liquid Local Tanker 260 km
6 Chloro Acetyl
Chloride Liquid Local Drums 260 km
7 Sulphuric acid Liquid Local Carboys 2 km
8 Aluminum
Chloride Solid Local Drums 260 km
9 Hydro Chloric
acid Liquid Local Carboys 2 km
10 Caustic soda Solid Local Bags 260 km
11 Sodium Hydro
Sulphide Solid Local Drums 220 km
12 Charcoal Solid Local Bags 700 km
13 Iso Propyl
Alcohol Liquid Local Tanker 180 km
14 EDTA Solid Local Bags 190 km
15 Tertiary
Butanol Liquid Import Drums 3492 km
16 N-N Di methyl
aniline Liquid Local Drums 170 km
17 Sodium bi
carbonate Solid Local Bags 220 km
18 T- Butyl
Chloro Acetate Liquid Local Drums 2 km
19
T- Butyl
Ammonium
Bromide
Solid Local Drums 170 km
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 14 MANUFACTURING :API BULK DRUGS
S.
No. Substance
Physical
State
Source of
Supply
Means of
Transportation
Distance of
supplier from
project site
(km)
20 Formic acid Liquid Local/Import Tanker 260 km
21 Acetone Liquid Local/Import Tanker 660 km
22 Caustic flakes Solid Local Bags 260 km
23
Ortho Chloro
Phenyl Di
phenyl Chloro
methane
Solid Import Drums 3492 km
24 Imidazole Solid Local/Import Drums 220/3492 km
25 Tri ethyl
Amine Liquid Local Drums 220 km
26 Phthalodinitrile Solid Import Drums 3492 km
27 Hydrazine
hydrate Liquid Import Drums 220 km
28 Acetic acid Liquid Local/Import Carboys 660 km
29 Methanol Liquid Local/Import Tanker 220 km
30 Bifonazole Solid Import Drums 3492 km
31
Pyridoxine
Hydro
Chloride
Solid Import Drums 3492 km
32 Diglyme Liquid Import Drums 220 km
33 Phosphorous
oxy chloride Liquid Local Carboys 35 km
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 15 MANUFACTURING :API BULK DRUGS
Table 3-3: Safe Storage and Handling of Hazardous Chemicals
S. No. Raw materials
Qty. Stored at a
time ,MT
Storage BP 0C MP
0C
Standard operating
Pressure & temperature Possible Type of
Hazards
Control
Measures
Provided Max Actual
Temp. Pressure
1 2,6 Di Chloro
Phenol 150 80 Drums 218-220 64-66 80-125 Atmospheric Corrosive Use PPES
2 Potassium
Carbonate 60 30 Bags Decomposes 891 80-125 Atmospheric Corrosive Use PPES
3 Toluene 21 15 Tank 110.6 -95 95-120 Atmospheric Flammable liquid Use PPES
4 Aniline 24 18 Tank 184.1 -6.3 70-80 Atmospheric Toxic Use PPES
5 Sodium
Methoxide 23 15 Tank >300 127 70-80 Atmospheric irritant, corrosive Use PPES
6 Chloro Acetyl
Chloride 20 15 Drums 106 -22 55-125 Atmospheric irritant, Toxic Use PPES
7 Sulphuric acid 0.6 0.3 Carboys 337 10 15-20 Atmospheric Corrosive Use PPES
8 Aluminum
Chloride 25 10 Drums 180 192.4 35-180 Atmospheric irritant, corrosive Use PPES
9 Hydro Chloric
acid 2 1 Carboys 110 -26 30-40 Atmospheric irritant, corrosive Use PPES
10 Caustic soda 20 10 Bags 1388 318 30-100 Atmospheric Corrosive Use PPES
11 Sodium Hydro
Sulphide 3 1.5 Drums 160 52 100 Atmospheric Flammable Solid Use PPES
12 Charcoal 4 2 Bags 4827 3500 70-85 Atmospheric Combustible Use PPES
13 Iso Propyl
Alcohol 20 12 Tank 82.6 -89 55-60 Atmospheric Flammable Liquid Use PPES
14 EDTA 0.6 0.3 Bags 382.4 220 55-60 Atmospheric irritant, Slight
Hazardous Use PPES
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 16 MANUFACTURING :API BULK DRUGS
S. No. Raw materials
Qty. Stored at a
time ,MT
Storage BP 0C MP
0C
Standard operating
Pressure & temperature Possible Type of
Hazards
Control
Measures
Provided Max Actual
Temp. Pressure
15 Tertiary Butanol 15 10 Drums 82.2 25.7 30-50 Atmospheric Flammable Liquid Use PPES
16 N-N Di methyl
aniline 3 2 Drums 194 52 30-50 Atmospheric Corrosive ,Toxic Use PPES
17 Sodium bi
carbonate 1 0.5 Bags 851 50 30-50 Atmospheric Combustible Use PPES
18 T- Butyl Chloro
Acetate 3 1.5 Drums 157 NA 70-85 Atmospheric Irritant ,Corrosive Use PPES
19
T- Butyl
Ammonium
Bromide 1 0.5 Drums 101 103 70-85 Atmospheric Irritant Use PPES
20 Formic acid 15 10 Tank 100.8 8.4 50-60 Atmospheric Corrosive Use PPES
21 Acetone 10 5 Tank 56 -95 50-60 Atmospheric Flammable Liquid Use PPES
22 Caustic flakes 20 10 Bags 145 323 30-100 Atmospheric Corrosive Use PPES
23
Ortho Chloro
Phenyl Di
phenyl Chloro
methane
7 5 Drums -- 135 30-60 Atmospheric Oxidizing Agent Use PPES
24 Imidazole 2 1 Drums 256 91 30-60 Atmospheric Toxic Use PPES
25 Tri ethyl Amine 1 0.8 Drums 89.5 -114.70 30-60 Atmospheric Flammable
liquid/Corrosive Use PPES
26 Phthalodinitrile 0.5 0.3 Drums 304 140 80-70 Atmospheric Toxic Use PPES
27 Hydrazine
hydrate 0.8 0.4 Drums 120 -52 70-80 Atmospheric Corrosive Use PPES
28 Acetic acid 0.6 0.4 Drums 118.1 16.6 40-50 Atmospheric Corrosive Use PPES
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 17 MANUFACTURING :API BULK DRUGS
S. No. Raw materials
Qty. Stored at a
time ,MT
Storage BP 0C MP
0C
Standard operating
Pressure & temperature Possible Type of
Hazards
Control
Measures
Provided Max Actual
Temp. Pressure
29 Methanol 12 10 Tank 64.7 -97.6 60-65 Atmospheric Flammable liquid Use PPES
30 Bifonazole 0.5 0.3 Drums 405 142 30-50 Atmospheric Toxic Use PPES
31 Pyridoxine
Hydro Chloride 0.6 0.3 Drums 491.90 214 25-30 Atmospheric Toxic Use PPES
32 Diglyme 0.2 0.1 Drums 162 -64 25-30 Atmospheric Flammable
liquid,Toxic Use PPES
33 Phosphorous
oxy chloride 0.5 0.2 Carboys 105.8 1.25 25-30 Atmospheric
Corrosive
liquid/Toxic Use PPES
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 18 MANUFACTURING :API BULK DRUGS
3.7 RESOURCE OPTIMIZATION/RECYCLING AND REUSE ENVISAGED
IN THE PROJECT
Resource optimization/recycling and reuse envisaged in the project are mentioned below;
Efficient cooling towers are being planned to reduce evaporation losses.
Adequate solvent recovery system shall be provided to recover more than 96%
and reuse the solvent and minimize the solvent loss.
Recovery of aluminum chloride solution, potassium chloride powder as a valuable
by-product.Availability of water resources, Energy/Power requirement and
source.
Product wise Solvent consumption (fresh and recovered) per tone and per month of
product after proposed expansion
Table 3-4: Details of Product Wise Solvent Consumption
S. No. Raw materials
Consumption in MT
Per tone Per Month
1.0 For Diclofenac Sodium & its Salts
1.3 Toluene (Recovered) 0.85 236.25
1.4 Toluene (Fresh) 0.075 10.875
2.0 For Aceclofenac
2.3 N-N Di methyl aniline (Recovered) 0.70 37.15
2.4 N-N Di Methyl Aniline (fresh) 0.07 1.35
2.10 Formic acid (Fresh) 0.12 6
2.11 Formic acid (recovered) 1.22 61
2.12 Acetone (Recovered) 0.938 46.9
2.13 Acetone (fresh) 0.10 5
2.16 Toluene (Recovered) 1.83 93.5
2.17 Toluene (Fresh) 0.096 2.8
3.0 For Clotrimazole
3.2 Toluene (recovered) 3.46 34.6
3.3 Toluene (fresh) 0.18 1.8
3.6 Acetone (Recovered) 7.65 76.5
3.7 Acetone (Fresh) 0.807 8.07
4.0 For Di Hydralazene Sulphate
4.4 Methanol (Recovered) 1.28 3.5
4.5 Methanol (fresh) 0.18 0.146
5.0 For Bifonazole
5.3 Acetone (Recovered) 5.66 28.3
5.4 Acetone (Fresh) 0.629 3.15
6.0 For Pyridoxine Acetonide Hydro Chloride
6.2 Acetone (Recovered) 1.16 2.9
6.3 Acetone (fresh) 0.336 0.84
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 19 MANUFACTURING :API BULK DRUGS
3.8 AVAILABILITY OF WATER ITS SOURCE, ENERGY/POWER
REQUIREMENT AND SOURCE SHOULD BE GIVEN
Availability of water its source, Energy/power required and its source is described below:
3.8.1 Water
Water withdrawal Permission is attached as Annexure 4.
Table 3-5: Details of Water Consumption
S. No. Particulars Existing
(KLD)
Proposed
(KLD)
After Proposed
expansion
(KLD)
1 Domestic 15.0 5.0 20.0
2 Processing & washing 55.0 88.0 143.0
3 Boiler 20.0 40.0 60.0
4 Cooling 20.0 55.0 75.0
5 Scrubber 5.0 2.0 7.0
6 Floor/container/equipment
washing 25.0 25.0 50.0
7 Gardening 10.0 5.0 15.0
Total 150.0 220.0 370.0
Total Industrial 125.0 210.0 335.0
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 20 MANUFACTURING :API BULK DRUGS
Figure 3-1: Water Balance Diagram of Existing Scenario
Figure 3-2: Water Balance Diagram after Proposed Expansion
Water Balance at Existing Scenario
Total Fresh water Consumption, 150 m3/day sourced from Water supply Department GIDC Vapi
Domestic: 15 Processing &
Washing: 55
Cooling: 20 Boiler: 20 Scrubber: 5 Floor/equip.Washing: 25 Gardening: 10
Septic tank: 12
Final Outlet ofETP
Concentrated: 5 Normal: 47
Salt: 0.75 Loss: 0.1 Condensate: 4.15
10 18 3 25
107.15 M3/day
Primary, secondary, tertiary ETP
CETP
Tidal Zone of river Damanganga to Arabian Sea
Water Balance After proposed expansion
Total Fresh water Consumption, 370 m3/day sourced from Water supply Department GIDC Vapi
Domestic: 20 Processing &
Washing: 143
Cooling: 75 Boiler: 60 Scrubber: 7 Floor/equip.Washing: 50 Gardening: 15
Septic tank: 17
Final Outlet ofETP
Concentrated: 18 Normal: 151
Salt: 2.7 Loss: 0.36 Condensate: 14.94
15 25 5 50
260.94 M3/day
Primary, secondary, tertiary ETP
CETP
Tidal Zone of river Damanganga to Arabian Sea
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 21 MANUFACTURING :API BULK DRUGS
3.8.2 Power
Table 3-6: Energy Requirements and Its Source
S.
No. Particulars Existing
After Proposed
expansion
Source
1.0 Steam
requirement
5500
kg/Hr 10500 Kg/Hr.
Will be obtained from existing as well
as new steam boiler
Table 3-7: Power Requirements and Its Source
S.
No. Particulars Existing
After
proposed
expansion
Source
1.0 Power – Electricity requirement 650 KVA 1600 KVA
Will be
sourced from
Dakshin
Gujarat Vij
Co. Ltd
3.9 QUANTITY OF WASTES TO BE GENERATED AND SCHEME FOR
THEIR MANAGEMENT/DISPOSAL
Quantity of waste to be generated (liquid and solid) and scheme for their Management/
disposal is enclosed as Annexure 5.
3.10 SCHEMATIC REPRESENTATIONS OF THE FEASIBILITY DRAWING
WHICH GIVE INFORMATION OF EIA PURPOSE
Schematic representation of the feasibility drawing which give information of EIA
purpose: A Schematic representation of the feasibility drawing is enclosed as Annexure
10
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 22 MANUFACTURING :API BULK DRUGS
4 SITE ANALYSIS
4.1 CONNECTIVITY
The project is located in notified Industrial Estate of Vapi which is very well connected to
National Highway 8 and Western Railways. The nearest airport is Mumbai which is 150 km
away from the project site by road.
4.2 LAND FORM, LAND USE AND LAND OWNERSHIP
The land is in the form of industrial shed owned by Gujarat Industrial Development
Corporation.
4.3 TOPOGRAPHY (ALONG WITH MAP)
Topography map showing the elevation of the study area is enclosed as Annexure 7
4.4 EXISTING LAND USE PATTERN
The existing land is located in the notified industrial area developed for chemical industrial
zone and a copy of gazette notification is enclosed as Annexure 9.
4.5 EXISTING INFRASTRUCTURE
GIDC notified industrial area of Vapi has available infrastructure like water, electricity,
roads, rail, transportation, availability of raw material and drainage system.
4.6 SOIL CLASSIFICATION
General soil classification of the area is as under:
Soil Characteristics & Land use classification: The study area is located at outer
part of Dadra. Northern part of the site is fully developed for settlement with
cropping pattern. Eastern part of the site location has Loamy, clay, Red soil.
The project site around 10 km radius has mixed soil type of Basalt soil and Clay
soil. This type of soil is not suitable for cultivation purpose.
The land is suitable for industrial development as it is notified by GIDC.
Damanganga River is located at 4 km distance from the site location; both side of the river
has mixed soil type (Sand, clay and Basaltic soil).
4.7 CLIMATIC DATA FROM SECONDARY SOURCES
Rainfall Data:
The project site location receives annual rainfall of 1200 to 1300 mm in 35 rainy days
having coefficient of variation of 65 %. There is large spatial and temporal variation in
rainfall of the study area. The low rainfall areas receiving less than 500 mm rainfall are
comprised of Kutch district and western parts of Banaskantha and Patan districts and parts
of Jamnagar, Rajkot and Surendranagar districts. These are also characterized by arid
climate. The high rainfall (> 1400 mm) receiving areas (Project site, Dang, Valsad, Navsari
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
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and Surat, Dadra & Nagar Haveli and Daman & Diu) are characterized as sub humid
climate. The remaining part of the state receives rainfall between 500-1000 mm and
generally falls under semi-arid climate. Considering the abnormality of weather particularly
rainfall during the monsoon period, the observed and predicted rainfall was then analyzed
for its validity.
Table 4-1: Rainfall projection for Project site and Gujarat for 2011 (June-Oct.)
S.
No Region
Rainfall Projection
(in mm) June – Oct
Normal Rainfall
(In mm)
Rainfall Projection
(% Departure from
normal)
1.0 Middle Gujarat 905.3 796 13.7
2.0 South Gujarat 696.3 575 21.0
3.0 Project site 2071.7 1433.7 44.5
4.0 Saurashtra 767.1 580.4 32.2
5.0 Gujarat State 1110.1 846.5 31.1
Source: AAU, Anand, Gujarat
Temperature Data:
The site is located in the southern part of Gujarat. The secondary data was collected from
free data of Worldclim.org for the year 2010. The project site temperature regime for
medium to high level temperature (30-32 °C) during the seasonal months (June to Sep).
4.8 SOCIAL INFRASTRUCTURE
Social Infrastructure in Valsad district is as under:
Education: There are 990 primary, 161 secondary and higher secondary schools.
There are 6 ITIs offering several industrial training Institutes programs which includes,
fitting, armature and motor rewinding, electrician, information technology and electronic
system maintenance etc., 166 Higher Secondary School, One Government polytechnic
College is present in the district offering courses in civil, chemical, electrical, mechanical
and plastic engineering, 6 nos. of ITI’s with an intake capacity of 360, 1 nos of Polytechnic
College With 120 seats, there is one Engineering College, Pharmacy College, Arts,
Commerce, Science, B. Ed and Law College. Valsad district also has instituteswhich offers
management studies with fulltime MBA.
Source: Department of Education, 2007
Health: There are 43 primary healthcare centres, 10 community healthcare centres, 10
Government and 1 Municipal hospital present in the district. Valsad has several private
specialized hospitals to provide a comprehensive range of tertiary and secondary care
services backed by state-of-the-art technology and trained medicos. A multi-specialty
Hospital, (branch of Nadkarni Group of Hospitals) is present in Vapi, providing services in
general and laparoscopic surgery, trauma, orthopedic and urology etc. The hospital is one of
the few centers in India offering Uterine Thermochoice Thermal Balloon Therapy for
Dysfunctioning Uterine Bleeding (DUB) patients. Beside this, several private hospitals such
as, Kasturba Hospital, Bhatia General Hospital and Adarsh Hospital are also present in
Valsad.
Tourism: The Tourism department built the Fire Temple at Udawada in 1742, which is also
known Fire Temple for the Parsi community in India, makes the city a famous pilgrimage
center throughout the world. Dharampur is surrounded on three sides by the Sahyadri
Mountains which grace the town with pleasant climate throughout the year. The collection
at the Lady Wilson Museum in Dharampur includes tribal art and art crafts that highlights
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
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the local culture. Besides this, District Science Centre is also present in Valsad Proximity of
Valsad with Daman & Diu, which has increased the graph of tourist flow in the district.
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5 PLANNING BRIEF
5.1 PLANNING CONCEPT
There is a cluster of numerous large-scale, medium-scale and small-scale industries,
engaged in the manufacture of variety of products like pharmaceuticals, dyes and
chemicals, paper mills, paints, plastics, packaging, textiles, specialilty chemicals, pesticides
and others in the Gujarat Industrial Development Corporation (GIDC) notified area of Vapi.
5.2 POPULATION PROJECTION
Not applicable
5.3 LANDUSE PLANNING
The existing as well as proposed expansion project is located within the Notified Industrial
Area by Government of Gujarat and due to the proposed project there will not be any
change in the land use pattern of the region. Proposed Green belt planning in the project
area is as below.
For Green Belt Development as per the revised layout plan, the company proposes 30%
green belt of the total land, i.e. 7801 sq. meter. The company shall develop green belt along
the periphery of the site and in common premises available outside the company premises.
While selecting the plants species to be grown in the green belt zone, following points will
be taken into account:
1. Climatic condition and soil characteristics of the region.
2. The air pollution emitted by the industry – gaseous and particulate matter. Plant
interaction with both gaseous and particulate pollutants and to a great extent absorbs
them and thus, removes them from the atmosphere.
3. Characteristics of plants including shapes of crowns considered necessary for
effective absorption of pollutant gases and removal of dust particles.
4. Height of the plants should not be too high to be lethal.
5. For absorbance of gases, the duration of the foliage should be longer.
6. Vegetation controls soil erosion rates significantly. The decrease of water erosion
rates with increasing vegetation cover is exponential. This review reveals that the
decrease in water erosion rates with increasing root mass is also exponential. Plant
species having good root system are selected, so that soil erosion can be checked.
Table 5-1: Area Statement of Existing and Proposed Expansion
S. No Particulars
Area in m2
Existing Proposed Total
1.0 Total Plot Area 7801 0 7801
1.1 Production Plant 1083.1 0 1083.1
1.2 Green Belt 1200 1200 2400
1.3 Solid Raw Materials Storage 500 200 700
1.4 OHC/EHS/security 21.13 0 21.13
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S. No Particulars
Area in m2
Existing Proposed Total
1.5 Solvent storage 200 200 400
1.6 Finished product storage area 500 0 500
1.7 ETP 250 250 500
1.8 Utility 278.07 0 278.07
1.9 Roads 100 0 100
1.10 Solid Waste Storage 170.08 0 170.08
1.11 Admin Building/ R&D/Toilets 242.75 0 242.75
1.12 Open Space 3255.87 -1850 1405.87
Map 5-1: Site Layout Map with Green Belt Development Planning
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND
There is no need for any infrastructure demand in terms of physical or social needs for the
proposed expansion Amenities/Facilities.
5.5 AMENITIES/ FACILITIES
GIDC notified industrial area of Vapi has the available infrastructure like water, electricity,
roads, rail, transportation, availability of raw material and drainage system.
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 27 MANUFACTURING :API BULK DRUGS
6 PROPOSED INFRASTRUCTURE
6.1 INDUSTRIAL AREA (PROCESSING AREA).
The proposed infrastructure to manufacture products will be built with standard engineering
design considering all the relevant parameters related to environment, health and safety.
6.2 RESIDENTIAL AREA
No residential area is involved in the proposed expansion project.
6.3 GREEN BELT
Green belt will be provided and maintained at the tune of 30% of the total land area.
6.4 SOCIAL INFRASTRUCTURE
Not applicable
6.5 CONNECTIVITY
The project site is very well connected by road through National Highway no. 8, western
railways.
6.6 DRINKING WATER MANAGEMENT
Drinking water is purchased from local suppliers.
6.7 SEWAGE SYSTEM
Source of water is from GIDC water supply services.
6.8 INDUSTRIAL WASTE MANAGEMENT
Industrial liquid effluent generated during the manufacturing of proposed expansion
product will be treated in the primary and secondary effluent treatment plant and
discharge into under ground effluent drainage line to CETP for further treatment and
disposal into tidal zone of River Damanganga.(Membership certificate is attached
as Annexure 6)
Generated domestic liquid waste is being disposed off through septic tank /soak pit.
Details of Solid/ Hazardous Waste management is given in following table:
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 28 MANUFACTURING :API BULK DRUGS
Table 6-1: Solid & Hazardous Waste Management
S. No.
Type of Solid &
Hazardous waste
(Hazardous waste
category)
Quantity, TPA
Place of
Storage Disposal
Existing
After
proposed
expansion
Hazardous Waste
1.0 Used oil (5.1) 0.24 0.3 HDPE Drum Sell to registered re-
refiner
2.0 Discarded
containers (33.1) 30.0 50.0 Pallets/drums
Sell to authorized
recycler
3.0 Process Residue &
waste (28.1) 12.0 1200.9 HDPE drums
Sell to actual &
authorized users
4.0 ETP waste, (35.3) 180 4900 HDPE bags Dispose off into
TSDF, Vapi
5.0 Spent Carbon (28.3) 48 192.0 HDPE bags
Sent for co-
processing to RSPL,
Panoli
6.0 Spent solvent (28.6) 20.0 622.764 Storage tank
Recovered in house
and recycled in the
process
7.0
Chemical Sludge
from high COD
stream (35.3) 6.6 0 HDPE drum
Sent to SEPPL,
Kutch for
incineration
8.0 Aluminum Chloride
Soln. (SCH: II, B10) 1500 6264 Storage tank
Sell to actual &
authorized users
9.0 Used Glass wool (Z-
22) 0.06 0.12 HDPE bags
Dispose off into
TSDF
10. Salt from MEE
(35.3) 0 842 HDPE bags
Dispose off into
TSDF
11.0
Inorganic Acid
(30% HCl) (Sch: II
B 15
0 2922 Storage tank Sell to actual &
authorized users
12.0 KCl Powder process
(28.1) 0 744 HDPE bags
Sell to actual &
authorized users
13.0 NaCl from process
(28.1) 0 272 HDPE bags
Sell to actual &
authorized users
Solid Non –Hazardous Waste
14.0 Fly Ash 145 (7%) 243 (7%) Silos Send to brick making
industries
(Membership certificates is attached as Annexure 6)
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 29 MANUFACTURING :API BULK DRUGS
6.9 POWER REQUIREMENT & SUPPLY/ SOURCE
Power requirement for proposed project will be taken from DGVCL.
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 30 MANUFACTURING :API BULK DRUGS
7 REHABLITATION & RESETTLEMENT (R & R)
PLAN
7.1 POLICY TO BE ADAPTED (CENTRAL /STATE) IN RESPECT OF THE
PROJECT AFFECTED PERSONS INCLUDING HOME OUTSEE, LAND
OUTSEE AND LANDLESS LABOURERS
There will be no rehabilitation and resettlement undertaken as labours and workers from
local & nearby areas for the proposed construction activity which will be minor as the
proposed expansion activity is to be undertaken at the existing site.
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 31 MANUFACTURING :API BULK DRUGS
8 PROJECT SCHEDULE AND COST ESTIMATE
8.1 LIKELY DATE OF START OF CONSTRUCTION AND LIKELY DATA OF
COMPLETION
After obtaining Environmental clearance and Consent to Establish from GPCB, the
company shall start the proposed construction and commissioning of the project and
complete the project within one year.
8.2 ESTIMATES PROJECT COST ALONG WITH ANALYSIS IN TERMS OF
ECONOMIC VIABILITY OF THE PROJECT
Estimated project cost along with the analysis in terms of economic viability of the project
is given in following table:
Table 8-1: Capital Cost Projection
S. No. Particluars Cost in Rs.(Lakh)
Existing Proposed Total
1.0 Land 117.25 0 117.25
2.0 Building 237.24 300.0 537.24
3.0 Plant & Machinery
3.1 Equipment & Machineries 1950.35 200.0 2150.35
3.2 Pipes & fittings 75.0 25.0 100.0
3.3 Utilities 125.0 35.0 160.0
3.4 Laboratory equipment 136.88 25.0 161.88
4.0 Environmental Management System
4.1 Effluent Treatment Plant 300.49 250.0 550.49
4.2 Air Pollution Control 55.0 20.0 75.0
4.3 Hazardous waste 25.0 150.0 175.0
5.0 Total Project Cost 3022.21 1005.0 4027.21
6.0 Utilities
6.1 Steam Boiler, TPH 3.0 +3.0 3.0 +8.0 11.0
6.2 Thermopak, lakh k cal 6.0 -6.0 0
6.3 Cooling Tower, TR 500 700 1200
6.4 Chilling plant, TR 250 200 450
6.5 D.G. Set (Standby), KVA 500 x 2 1250 1250
7.0 Power from DGVCL, KVA 650 950 1600
8.0 Fuel for utilities
8.1 Coal for boiler, kgs/hr 583 972 1555
8.2 Furnace oil for boiler & thermopak, kgs/hr 64 -64 -
8.3 HSD for D G set, Kgs/hr 220 0 220
9.0 Water from GIDC, Vapi, M3/day 150.0 220.0 370.0
10.0 Waste water generation,M3/day 108.0 156.0 264.0
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 32 MANUFACTURING :API BULK DRUGS
Table 8-2: Project Viability
S.No. Particluars Amount (INR Cr.)/Annum
1.0 Proposed Sale 168.0
2.0 Raw Material Cost 60.60
3.0 Power & Fuel 15.0
4.0 Labour Cost 9.33
5.0 Environmental Management System 9.17
6.0 Maintenance Cost 10.29
7.0 Selling, Packing & Office Expenses 11.0
8.0 Proposed Profit 52.61
The company will provide budgetary provision for the recurring expenses for environmental
issues while planning the allocation of funds during the annual budgetary planning.
Table 8-3: Recurring/operating Cost Per Annum
S. No. Component Proposed
(Rs. in Lakh/annum)
1.0 Environment & Safety Management System 217.0
2.0 Greenbelt Maintenance 4.0
3.0 Solid/hazardous waste Disposal 155.0
Total 376.0
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 33 MANUFACTURING :API BULK DRUGS
9 ANALYSIS OF THE PROPOSAL (FINAL
RECOMMENDATIONS)
9.1 FINANCIAL AND SOCIAL BENEFITS WITH SPECIAL EMPHASIS ON
THE BEFIT TO THE LOCAL PEOPLE INCLUDING TRIBAL
POPULATION, IF ANY, IN THE AREA
Proposed expansion activity will provide benefits to the local people in terms of financial
and social welfare.
Local people will get direct financial benefit by way of employment.
Local people will get some contracts of supply and services to get indirect income.
Company will contribute in improving education and health facilities in nearby area
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 34 MANUFACTURING :API BULK DRUGS
ANNEXURE
S
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 35 MANUFACTURING :API BULK DRUGS
Annexure 1: Location map showing the Project site and inter-state boundary within 5
kms radius
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 36 MANUFACTURING :API BULK DRUGS
Annexure 2: Site Layout Plan
Google Image
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 37 MANUFACTURING :API BULK DRUGS
Annexure 3: Manufacturing Process with Chemical Reactions and Mass Balance
1. Diclofenac Sodium
2, 6 - Dichlorophenol is reacted with MMCA, Aniline & Chloro Acetyl Chloride and
AlCl3 to yield (2, 6 - Dichlorophenol) Indolinone is hydrolyzed using isopropyl alcohol
and sodium hydroxide to give crude Diclofenac Sodium. This on purification using
deminerlised water and isopropyl alcohol gives the pure Diclofenac Sodium.
Cl Cl
OH
DCP
163
+ Cl CH2COOCH3
MMCA
108.5
K2CO3
138
Cl Cl
CH2 COOCH3
235
Cl Cl
OCH2 COOCH3
235 SMO
54
NH2
+ CH3ONa
Aniline
93
+ NH Cl
Cl
238
2:6 Di Chloro Di phenyl Amine
32
Methanol
112
NH
Cl Cl
+ ClCH2COCl
CAC
113
N
Cl Cl
-CH2COCl + HCl
314
N Chloro Acetyl 2:6 Di chloro di phenyl amine
+ CH3OH + CH3COOCH2ONa
238
2:6 Di Chloro Di phenyl Amine
36.5
+ KCl + KHCO3
74.5 100
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EXPANSION PROJECT: 38 MANUFACTURING :API BULK DRUGS
N
Cl Cl
-CH2COCl + AlCl3
133.4
N
Cl Cl
+ AlCl3 + HCl
133.4 36.5
278
Indolinone
N
Cl Cl
+ NaOH
40
NH
Cl Cl
318
Diclofenac Sodium
CH2COONa
278
Indolinone
314
N Chloro Acetyl 2:6 Di chloro di phenyl amine
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 39 MANUFACTURING :API BULK DRUGS
(1.0) Mass Balance of Dichlofenac Sodium
REACTOR
2,6 DCDPA: 4380.35 kgsToluene (F): 132.2 kgsToluene (R): 2189.8 kgsChloro Acetyl Chloride: 2080 kgsSoda ash: 29.25 kgsSulphuric acid: 29.25 kgsWater: 3600 kgs
FILTERATION & WASHINGWater: 7500 kgs Wash Water: 7500 kgs
PADDLE VACCUM DRYER
N Chloro Acetyl (2,6 Di Chloro Di Phenyl Amine): 5787.87 kgs
GLASS LINED REACTORAluminum Chloride: 2454.5 kgs HCl gas: 671.59 kgs Scrubber HCl (30%): 2238 kgs
Water: 1564 kgs
REACTORWater: 8776.6 kgsHCl: 292.50 kgs
Aluminum Chloride Solution (10-12%): 11523.6 kgs
CENTRIFUGEWater: 5851.12 kgsHCl: 292.50 kgs
Waste Water: 6143.62 kgs
Indolinone: 5115.10 kgs
SS REACTORCaustic: 736kgsSodium Hydro Sulphide: 175.53 kgsWater: 8776.66 kgs
CENTRIFUGEWater: 2925.55 kgs Waste Water: 11877.74 kgs
DICHLOFENAC SODIUM CRUDE:
SS REACTORCharcoal: 331 kgsWater: 24496.5 kgsIPA: 331 kgsEDTA: 9.93 kgs
SPARKLEER Waste Charcoal: 331 kgs
CENTRIFUGEWater: 24496.5 kgsIPA: 496.55 kgs
Waste Water: 49830.48 kgs
VACUM DRYER
DICLOFENAC SODIUM SALT: 5851.10 KGS
REACTOR(9362.86 KGS)
2,6 DCP: 3000 kgsK2CO3: 1269.93 kgsToluene (F): 309.6 kgsToluene (R): 2786.4 kgs
REACTOR
Waste Water: 165.64 kgsCarbon dioxide: 404.90 kgs
DistillationToluene Recovered: 2786.4 kgsDistillation residue: 77.4 kgsLoss: 232.2 kgs
Water: 4200 kgsKCl Solution: 5571.16 kgs (24.61%) Distillation KCl Powder (by-product): 1371 kgs
Waste water: 4200 kgs
REACTORAniline: 1711.65 kgsSodium methoxide: 3975.44 kgs (25%) Distillation
Methanol Recovered: 3213 kgsDistillation residue: 89.23 kgsLoss: 267.75 kgs
REACTORWater: 1600 kgsMethanol Recovered: 588.95 kgsSodium Glycolate: 1803.67 kgsWaste water: 1268.72 kgs2,6 Di Chloro Di ethyl Amine: 4380.35 kgs
HCl Gas: 671.61 kgs Scrubber 30% HCl: 2238 kgs
Water: 1564 kgs
Distillation Toluene recovered: 2189.8 kgsDistillation residue: 58.05 kgs kgsLoss: 133.17 kgsWaste Water: 3600 kgs
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 40 MANUFACTURING :API BULK DRUGS
2. Aceclofenac
Stage-1: T Butanol and Chloro Acetyl Chloride react in presence of NN Dimethyl
Aniline at low temperature. After reaction organics mass wash with water and
sodium bicarbonate solution to get stage-1
Stage-2: Stage-I react with Diclofenac Sodium in presence of TBAB in Toluene
media, further react with formic acid and reaction mass quenching in water and
product is isolated by filtration. Finally Crude Aceclofenac purified in ethyl acetate
and charcoal. Pure product isolated by filtration.
CH2COONa
NH
Cl Cl
CH2COOCH2COOC (CH3)3
NH
Cl Cl
410
CH3
CH3
+ CH3 COOCH2Cl C
+ NaCl
58.5
150.5
t-Butyl Chloro Acetate
318
CH2COOCH2COOC (CH3)3
NH
Cl Cl
410
+ HCOOH
46
Formic Acid
CH2COOCH2COOH
NH
Cl Cl
354
+ HCOOC(CH3)3
Salt
102
Aceclofenac
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 41 MANUFACTURING :API BULK DRUGS
3. Clotrimazole
Clt CL (Ortho Chloro Tritryl Chloride) and Imidazole is heated in Toluene in presence of
Triethyl Amine, wash organics layer by water finally distill out Toluene to get Crude Clt
CL.
Crude Clt CL purified in Acetone and Activated charcoal and pure product is isolated by
filtration.
Mass Balance of AceclofenacChloro Acetyl Chloride : 1000 KgsT- butanol : 670 KgsNN Dimethyl Aniline (R) : 981.0 KgsNN Di methyl aniline (F): 109 kgsSodium Bicarbonate : 15 KgsWater : 3000 KgsHCl : 20 Kgs
Sodium chloride : 229.95 KgsWaste Water : 1875 Kgs
ANF
Water: 1000 kgsCaustic Flakes : 500 Kgs
GLASS LINED REACTOR
NN Dimethyl Aniline DistillationRecovery : 981.003 Kgs
Residue : 26.78 KgsLoss : 80.32 KgsWater : 4552.031 KgsT-butyl Chloro Acetone : 1331.85 Kgs
GLASS LINED REACTOR
GLASS LINED REACTOR
GLASS LINED REACTOR
Diclofenac Sodium : 1250 KgsT-butyl Chloro Acetate : 750 KgsTBAB : 15 KgsWater : 1875 Kgs
GLASS LINED REACTOR
Water : 3750 KgsToluene (R) : 2553.12 KgsToluene (F): 134.38 kgs
Formic Acid (F) : 180.81 KgsFormic acid (R): 1699.19 kgs
Waste Water : 3750 KgsSalt : 400.95 Kgs
Formic ML Toluene ML Distillation
Toluene Recovered : 2553.12 KgsResidue : 80.01 KgsLoss : 77.025 KgsDRYER
HCl gas : 323.016 Kgs Scrubber HCl (30%): 1076 kgs
Water: 753 kgs
Distillation Formic Recovered : 1699.19 KgsResidue : 50 KgsLoss : 100.75 Kgs
SS REACTOR
ANF
Acetone (R): 1306.82 KgsAcetone (F): 145.2 kgsCharcoal : 13 KgsWater: 960 kgs
Charcoal Sludge : 13 Kgs
DRYER
Aceclofenac : 1391.50 Kgs
Acetone Recovered: 1306.82 kgsResidue: 59.96 kgsLoss: 85.24 kgsWaste water: 960 kgs
Cl H
313
N
+ C
Cl
N
344.5
C N N
+ HCl
68 36.5
Ortho Chloro trityl chloride Imidazole Clotrimazole
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 42 MANUFACTURING :API BULK DRUGS
4. Bifonazole :
Stage-I: Bifinyl and Benzoyl Chloride react in presence of AlCl3 in EDC at low
temperature. Reaction mass quenching in water and HCl. Materials isolated by
filtration.
Stage -II: Stage -I react with sodium borohydrate in presence of NaOH in IPA.
Reaction mass acidify with HCl. Distilled out IPA and add water in reaction mass.
Product isolated by filtration.
Stage-III: Stage-II reacts with Imidazole in presence of Thionyl Chloride in Toluene.
Organic layer wash with water distilled out Toluene to get Crude Bifonazole.
Crude materials purified in Acetone and Charcoal. Pure materials isolated by filtration.
GLASS LINED REACTOR
SS REACTOR
Mass Balance of Clotrimazole
CENTRIFUGE
Ortho -Chloro Phenyl DiphenylCloromethane : 300 Kgs Toluene (R) : 1143.80 KgsToluene (F): 60.2 kgsImidazole : 90 KgsTEA : 120 KgsWater : 600 KgsAcetone (R) : 1244.25 KgsAcetone(F): 138.25 kgs
Charcoal : 10 KgsAcetone (R) : 1283.75 KgsAcetone (F): 128.37 kgs
Toluene Recovered : 1143.80 KgsAcetone Recovered : 1244.25 KgsLoss : 198.45 Kgs
SPARKLER FILTER
GLASS LINED REACTOR
CENTRIFUGE
DRYER
Carbon Waste : 10 Kgs
Acetone Recovered : 869 Kgs
Acetone (Recovered) : 286.375 KgsLoss : 128.375 Kgs
CLOTRIMAZOLE : 330.2 Kgs
Waste water : 744.83 kgs
HCl gas : 34.97 KgsScrubber HCl (30%): 116.56 kgs
Water: 81.59 kgs
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 43 MANUFACTURING :API BULK DRUGS
+ COCl + AlCl3
Biphenyl
154
Benzyl Chloride
140.5 133
C
O
+ HCl + AlCl3
36.5 133
Ketone
258
Stage: 1
Stage: 2
C
O
+ NaBH4
Ketone
258
C
H
H
Sodium Borohydrate
68
Carbinol
260
+
Salt
(27)
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 44 MANUFACTURING :API BULK DRUGS
5. Di Hydralazene Sulphate
Dihydrallazine Sulphate is also known as nepresol sulphate or 1-4, dihydrazino-
phthalazine sulphate is manufactured by the condensation of phthalodinitrile (phthalic
acid dinitrile) with hydrazine hydrate in the presence of acetic acid glacial in methyl
alcohol. The base is then converted into the soluble acetate and precipitated as sulphate
containing two molecules of water of crystallization. Phthalodinitrile is reacted with
Hydrazine Hydrate in Methanol with catalytic quantity of Acetic Acid at 65 - 700 C to
get Azinothalazine base. This is converted into acetate by treating with dilute Acetic
Acid. The resulting solution is filtered where the crude Dihydrallazine Sulphate is
precipitated with Sulphuric Acid. The crude Sulphate is dissolved in hot water, treated
with activated Carbon and filtered and the clear filtrate cooled to get pure crystals of
Dihydrallazine Sulphate. The residue after recovery of Methanol from the methanolic
mother liquors is discarded or treatment in effluent treatment plant. Gases generated
from the 2nd
stage will be Scrubbed Off in Scrubber.
GLASS LINED REACTOR
Mass Balance of Bifonazole
CENTRIFUGE
Bifonazole Hydrochloride : 325 KgsGlacial Acetic acid : 310 KgsWater : 1300 Kgs
SPARKLER
GLASS LINED REACTOR
CENTRIFUGE
DRYER
Acetone (R) : 1480 KgsAcetone (F): 100 kgs
Acetone Recovered : 1323.25 Kgs
GLASS LINED REACTOR
Water : 650 Kgs Waste Water : 2294 Kgs
BIFONAZOLE : 291 KGS
Acetone Recovered : 326.27 KgsLoss : 183.28 Kgs
Acetone (F) : 83.28KgsAcetone (R): 169.52 kgs
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 45 MANUFACTURING :API BULK DRUGS
CN
CN
N
N
NH – NH2
NH – NH2
+ 2NH3
34
+ 3 NH2 NH2
Hydrice
Hydrite
96 Phthalodinitrile
C8 H4 N2
128 190
C8H10N6
N
N
NH – NH2
NH – NH2
190
C8H10N6
+ H2SO4
98
N
N
NH – NH2
NH – NH2
C8H12N6SO4
288
H2SO4
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 46 MANUFACTURING :API BULK DRUGS
Stage: 3
+
SOCl2
119
C
H
H
+ 2 HCl + SO2
73 64
Carbinol
260
N
N
H
+
C
H
N
Bifonazole
309
N
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 47 MANUFACTURING :API BULK DRUGS
6. Pyridoxine Acetonide Hydro Chloride
Pyridoxine Hydrochloride reacts with Acetone in presence of phosphorous oxychloride
and Deglyme to obtain Pyridoxine Acetonide Hydrochloride.
Mass Balance of Di Hydralazene Sulphate
GLASS LINED REACTOR
Phthalodinitrile : 100 KgsHydrazine Hydrate : 205 KgsAcetic Acid : 32 KgsMethanol (R) : 383.94 KgsMethanol (F): 42.66 kgsWater : 300 Kgs CENTRIFUGE Water To ETP : 457 Kgs
DHY BASE : 148.44 KGS
DM Water : 3465 KgsAcetic Acid : 55 KgsCharcoal : 5.0 KgsSulphuric Acid : 90 Kgs
SPARKLER FILTER Charcoal : 5.0 Kgs
CENTRIFUGE Waste water: 3610 Kgs
DHY SULPHATE CRUDE : 225 KGS
Water : 300 kgs
DM Water : 2950 KgsCharcoal : 12.0 Kgs
DRYER
SPARKLER FILTER Charcoal : 12.0 Kgs
CENTRIFUGE Waste Water : 3250 Kgs
DI HYDRALAZENE SULPHATE : 225 KGS
GLASS LINED REACTOR
GLASS LINED REACTOR
DistillationMethanol Recovered: 383.94 KgsResidue : 6.75 KgsLoss : 35.91 Kgs
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 48 MANUFACTURING :API BULK DRUGS
NCH3
OH
O
O
N
CH2OH
CH3
OH
OH.HCl + POCl3 + CH3 C CH3
O
+ Diglyme
CH3
CH3
. HCl
+ POCl3 + H2O + Diglyme
PyridoxineHydro Chloride (205.64)
Acetone ( 58)
Pyridoxine Acetonide Hydro Chloride (245.64)
Pyridoxine Hydro Chloride: 250 kgsAcetone (R) : 333.93 kgsAcetone (F):100.57 kgsDiglyme: 50 kgsPhosphorous Oxychloride : 188 kgs
GLASS LINED REACTOR
FILTERATION
TD
Acetone Recovered : 333.93 kgsLoss : 37.10 kgsML TO ETP : 225.85 kgs
Pyridoxine Acetonide Hydrochloride : 298.62 kgs
Mass Balance of Pyridoxine Acetonide Hydrochloride
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 49 MANUFACTURING :API BULK DRUGS
Annexure 4: Water Requirement Letter from GIDC
PREFEASIBILITY REPORT M/S AMOLI ORGANICS PVT. LIMITED
EXPANSION PROJECT: 50 MANUFACTURING :API BULK DRUGS
Annexure 5: Quantity of Waste Water (liquid waste) Generated and its Management
Table 1: Quantity of Waste water (liquid waste) generated and its management
Details of Effluent Treatment Plant with proposed modification
Product : API Bulk drugs
Source of effluent : Process, washing & utilities
Actual Flow : 264 kl/day (246 kl/day normal +18 kl/day Concentrated)
Design flow of effluent : 300 kl/day
Design parameter : As under
Table 2: Quantity of Waste water (liquid waste) generated and its management
Parameters
Concentrated
effluent
to MEE
Normal
effluent
MEE
condensate CETP inlet norms
pH 6.5 5.8 7.1 6.5-8.5
Temperature 28°C 28°C 35 40
Color (pt.co. scale), Units 172 145 65 <100
Suspended Solids, mg/l 220 356 20 <300
Oil and Grease, mg/l 2 30 0.2 <10
Phenolic Compound, mg/l 2.5 1.28 0 <1
Cyanides, mg/l ND ND 0 <0.1
Sulphides, mg/l ND 0.6 0 <2
Ammonical Nitrogen, mg/l ND 46 20 <50
BOD (5 days at 200C), mg/l 7200 1500 735 <400
COD, mg/l 23110 4200 2100 <1000
Chlorides, mg/l 25400 1400 160 -
Sulphates, mg/l 95302 120 20 -
S.
No. Particulars
Effluent Generation, m3/day
Normal Effluent Concentrated Effluent
Existing Proposed Total Existing Proposed Total
1 Domestic 12.0 5.0 17.0 0 0 0
2 Processing & washing 47.0 104.0 151.0 5.0 13.0 18.0
3 Boiler 18.0 7.0 25.0 0 0 0
4 Cooling 10.0 5.0 15.0 0 0 0
5 Scrubber 3.0 2.0 5.0 0 0 0
6 Floor/container/equipment
washing 25.0 25.0 50.0 0 0 0
7 Total 115.0 148.0 263.0 5.0 13.0 18.0
8 Total Industrial 103.0 143.0 246.0 5.0 13.0 18.0
9 Mode of Treatment CETP CETP CETP MEE MVR MVR
10 Condensate from MEE to
ETP 4.15 - 14.94 - -
11 Net Discharge to ETP 107.15 - 260.94 - -
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Parameters
Concentrated
effluent
to MEE
Normal
effluent
MEE
condensate CETP inlet norms
Total Dissolved Solids, mg/l 150500 6300 200 -
Phosphate, mg/l 3.8 2.5 0 <5
Based on the above criteria effluent treatment plant having under mentioned specification is
required to install:
Details of Effluent Treatment Plant for concentrated stream with proposed
modification:
Concentrated effluent flow: 18 Kl/Day:
Table 3: Details of Modification in Existing ETP for Proposed Expansion
Sr. No. Name of the Equipment
Capacity per day
Total
Existing Proposed
1 Collection tank 10 KL 10 KL 20 KL
2 Neutralization tank 10 KL 10 KL 20 KL
3 Filter nutsch 5 KL 15 KL 20 KL
4 Holding tank 5 KL 10 KL 15 KL
5 Stripper feed tank 10 KL 10 KL 20 KL
6 Solvent stripper 5 KL 15 KL 20 KL
7 MVR Feed tank 5 KL 10 KL 15 KL
8 MVR condensate storage tank 5 KL 10KL 15 KL
9 MVR 20 Kl 0 20 KL
10 Crystallizer 5 KL 25 KL 30 KL
Figure 1: Flow Diagram of MVR
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Figure 2: Flow Diagram of Treatemnt Scheme fro Concentrated Effluent
Details of effluent treatment plant for normal effluent
Brief process of waste water treatment:
Collection/Equalization Tank( ET-1) :- The effluent from different production plant &
utility comes thru gravity & pH maintain up to neutral with hydrated lime mixing with
surface aerator .
Equalization /Neutralization Tank ( ET-2) : Effluent from ET-1 is transfer into this tank
thru gravity, these waste water are treated with Fenton treatment system followed by
sulphuric acid, ferrous Sulphate & Hydrogen peroxide .
Flash Mixture :- Effluent is taken from ET-2 after Fenton Treatment into this tank thru
pump. this effluent is treated by dosing of Coagulant / Flocculent for flocculation. Primary
Settling Tank : The flocculates effluent is stay for separation of solid& liquid, the upper
Supernant layer is going into Biological ( secondary ) treatment thru gravity & lower sludge
layer sludge is transfer into sludge holding tank for filtration.
Concentrated effluent collection tank
Neutralization Tank
Solvent stripper
MVR feed Tank
Pre-heat exchanger
Polymer heat exchanger MVR Reactor
Crystalizer
Salt to TSDF
Solvent recovered
Condensate
To ETP
Flow Diagram of Treatment scheme for Concentrated effluent
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Filter Press: Filter the material from Sludge holding tank the filtrate taken into ET-02 &
Solid material filled into HDPE woven bag, this bags are stored in separate storage area &
final disposed to TSDF site..
Secondary Effluent Treatment Plant:
Aeration TankNo-1 ( AT-1 ) : Primary treated effluent goes to AT-1 thru gravity , aeration
tank is operated by providing air thru air blower for maintain dissolve oxygen for develop
biomass activity.
Secondary Settling Tank ( SST-1) : AT-1 treated effluent is going into SST-1 thru
gravity, here Supernant upper layer goes to Aeration -2 for further treatment & lower layer
use as RAS or excess sludge transfer into sludge holding tank for filtration.
Aeration Tank No-2 ( AT-2 ) :Effluent from SST-1 is taken into AT-2 & here biomass
maintained by providing air & after treated effluent goes into SST-2.
Secondary Settling Tank ( SST-2): Effluent treated after AT-2 is comes into SS-2 for
settling ,the upper supernet later are goes for further treatment to Tertiary treatment &
Lower layer use as RAS or send to sludge holding tank for filtration.
Tertiary Treatment Plant:
Sand& Carbon Filter: Secondary treated effluent passed thru sand& carbon filter & final
treated effluent send to Common effluent treatment plant (CETP) thru under ground GIDC
drainage system for further treatment & disposal as per GPCB guideline.
Normal effluent quantity: 260.94 m3/day
Table 4: Capacity of ETP along with Sizing
S.
No. Name of equipments Size
Capacity, M3
Existing Proposed Total
1 Oil & Grease separator 1 M*2M*1.2M 4.8 0 4.8
2 Lime Dosing Tank -- 1.0 4.0 5.0
2 Equalization cum neutralization
tank ( ET-1) 8M*8M*3.2M 205 0 205
3 Equalization cum neutralization
tank ( ET-2) 8M*8M*3M 192 0 192
4 Flash Mixture 1M*1M*1M 1.0 4.0 5.0
5 Primary settling tank 3M*3M*2.5M 22.50 25.0 47.5
6 Aeration Tank ( AT-1) 10M*10*5M 500 0 500
7 Aeration Tank ( AT-2) 10M*4*5M 200 0 200
8 Secondary Settling tank(SST-1) 4.4M*2.6M*2.5M 30 0 30
9 Secondary Settling tank(SST-2) 4M*2.6M*2.5M 30 0 30
10 Treated effluent holding tank 4M*2.6M*2.5M 30 0 30
11 Sludge Holding tank 2M*2.6M*1.5M 7.8 0 7.8
12 Sand filter 0.8M
(Dia)*1.250M(Length) 10 / 0 10
13 Carbon Filter 0.8M
(Dia)*1.250M(Length) 10 0 10
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Table 5: List of ETP Equipments
S. No. Name of equipments Qty. Size
1 Agitator for lime dosing tank Motor/pump
2 Floating aerator
Equalization cum neutralization tank ( ET-1)
1
5 HP
3 Floating aerator
Equalization cum neutralization tank ( ET-2)
1
5 HP
4 Transfer pump at Equalization tank 1+1+1 7.5/5/5 HP
5 Agitator for flax mixture 1 0.5 HP
6 Primary Sludge pump 1+1 2 HP
7 Agitator for poly pre. tank 1+1 0.5 HP
8 Air Blower(twin lob) 1+1 25 HP
9 Air Blower(twin lob) 1+1 15 HP
10 Sludge recycle pump( AT-1) 1+1 2 HP
11 Sludge recycle pump( AT-2) 1+1 2 HP
12 Agitator for Sludge Holding tank 1 2 HP
13 Filter press feed tank 1+1 2 HP
14 Filter press Hydraulic auto 1 33 plats
15 Sand/Carbon filter pump 1+1 2 HP
Figure 3: Flow Diagram of ETP
Collection
Tank
Dosing
Tank
Eff luent Transfer
Pumps
Equalization Cum
Neutralization tank
Flash Mixer
Polyelectrolyte
dosing Tank
Primary
Settling
Tank
Alum dosing
Tank
Aeration
Tank - 1
Aeration
Tank - 2 Treated
Eff luent
To
Vapi CETPdosing
Tank
Sludge Recycle
Pump
Sludge Recycle
PumpSludge Holding
Tank
Sludge Transfer
Pumps
Filter Feed
Pumps
Filter Press
Filtrate
To
Equalization
Tank
Poly. dosing
Tank
Flow Diagram of Effluent treatment plant
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Annexure 6: Membership Certificate of CETP, Vapi for Existing and Additional Effluent
Load
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Membership Certificate of TSDF Vapi and RSPL, Panoli and SEPPL, Kutch for Co-
Processing and incineration
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Annexure 7: Toposheet Map of Vapi Region
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Annexure 8: Copy of Plot Allotment Letter issued by GIDC
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Annexure 9: Letter Regarding the Unit is Located In Notified Industrial Area
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Annexure 10: A Schematic Representation of the Feasibility Drawing
Type of Industry
Existing unit mfg. of "API Bulk drugs
Type of cataegory as per EIA notification
(Catagery -5(f)-b
Proposed Activity:
The proposed expansion project involves the production of "API bulk drugs"
Submission of Form-1 and Pre-Feasibility
Report & Draft TOR
Resource requirments
Raw Material : Sourced from Manufacturer / Traders of the same.
Land: proposed expansion project in Existing plot ,At GIDC Vapi
Water: will be sourced through GIDC water supply.
Power: power will be sourced through Dakshin Gujarat Vij Co. Limited
Env. Mgt. Plan (EMP)
Air Pollution Control Measures: Adequate air pollution control system will be installed.
Water Pollution : normal Effluent will be treated in primary followed by tertiary ETP and discharge into CETP, Vapi and concentrated effluent will be sent to MEE.
Greenbelt Area: 30% of the Total Area will be developed.
Health & Safety measures will be followed properly.
Domestic: Will be disposed off through Soak pit, overflow sent to CETP
Industrial:: normal Effluent will be treated in primary followed by tertiary ETP and discharge into CETP, Vapi and concentrated effluent will be sent to MEE.
Gas emissions: Adequate capacity of MDC followed by bag filter and 30 meters height of chimney provided to coal fired steam boiler. Adequate capacity of two stage scrubbing system will be provided.
Hazardous waste: will be disposed off as per hazardous waste 2016
Fugitive emission: efficient control system
Public consultancy: Not required as the project is
located in GIDC Estate
Presentation before the EAC for TOR/EC
Site location :
The company located at Plot No.322/4, 40 shed, GIDC Vapi, Di:
Valsad
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Annexure 11: Details of Air Pollution & Its Control Measures at Existing & After
Proposed Expansion
Flue Gas Emission:
At present, the unit is having one number of 3 TPH of coal fired steam boiler, one
number of 3 TPH oil fired steam boiler and one number of 6 lakh k cal/hr capacity of oil
fired thermopak. Adequate capacity of multi cyclone separator followed by bag filter
and separate 30 meters height of chimney provided. The unit is proposes to install
additional one number of 8 TPH coal fired boiler having ESP and 30 meters height of
chimney will be provided. After proposed expansion, existing oil fired 3 TPH of steam
boiler and existing 6 lakh k cal/hr of thermopack will be discontinued.
At present, the unit is having two numbers of 500 KVA of D G set (standby). It will be
used only during power failure. The unit is proposed to install one number of 1250
KVA capacity of D G set (standby). After proposed expansion, existing 500 KVA x 2
numbers of S G sets will be discontinued.
Process Gas Emission:
Presently the unit has installed one number of two stage graphite followed by alkali
scrubber and 11 meters height of vent to scrub and recover HCl gas generated from the
process. After proposed expansion, the unit shall install additional one number of two
stage graphite followed by alkali scrubber and 11 meters height of vent to scrub and
recover HCl gas and SO2 generated from the process.
Details of Air pollution control measures are given in following table:
Table 1: Flue Gas Emissions
Sr.
No. Particulars
Details
Remarks
Existing Proposed
After proposed
Expansion
1.0 Capacity of
steam boiler: I 3 TPH 0 3 TPH
Existing 1.1 Fuel used Imported coal 0 Imported coal
1.2
Fuel
consumption,
kgs/hr
583 0 583
1.3 APC MDC & bag
filter 0 MDC & bag filter
1.4 Chimney 31 meters 0 31 meters
2.0 Capacity of
steam boiler: II 3 TPH 0 3 TPH
Will be
discontinued
after proposed
expansion
2.1 Fuel used FO/LDO 0 FO/LDO
2.2
Fuel
consumption,
kgs/hr
29 0 29
2.3 APC - 0 -
2.4 Chimney 31 meters 0
3.0 Capacity of 6 lakh k cal 0 6lakh k cal Will be
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Sr.
No. Particulars
Details
Remarks
Existing Proposed
After proposed
Expansion
Thermopack: I discontinued
after proposed
expansion 3.1 Fuel used Furnace oil 0 Furnace oil
3.2
Fuel
consumption,
kgs/hr
35 0 35
3.3 APC - - -
3.4 Chimney 31 meters 0 31 meters
4.0 Capacity of
Boiler: III 0 8 TPH 8 TPH
Proposed new
4.1 Fuel used 0 Imported coal Imported coal
4.2
Fuel
consumption,
kgs/hr
0 972 972
4.3 APC 0 ESP ESP
4.4 Chimney 0 30 meters 30 meters
5.0 Capacity of D G
set: I & II 500 KVA x 2 0 500 KVA x 2
Will be
discontinued
after proposed
expansion
5.1 Fuel used HSD 0 HSD
5.2
Fuel
consumption,
kgs/hr 220 0 220
5.3 APC 0 0 0
5.4 Chimney 11 meters 0 11 meters
6.0 Capacity of D G
set: III 0 1250 KVA Proposed New
6.1 Fuel used 0 HSD
6.2
Fuel
consumption,
kgs/hr
0 220
6.3 APC 0 0
6.4 Chimney 0 11 meters
Expected
emissision
PM: <150 mg/Nm3
SOX: < 100 ppm
NOX: < 50 ppm
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Table 2: Process Gas Emissions
Sr.
No. Particulars
Details
Remarks
Existing Proposed After proposed
Expansion
7.0 Stack attached to Reactor Reactor Reactor
Total two
numbers of
scrubbing
system
7.1 APC provided
Two stage
graphite
followed by
alkali
scrubber
Two stage
graphite
followed by
alkali
scrubber
Two stage graphite
followed by alkali
scrubber
7.2 Height of vent 11 meters 11 meters 11 meters
Expected
Emission
HCl: <20 mg/Nm3
Cl2 : < 9 mg/Nm3
SO2: < 40 mg/Nm3
DETAILS OF AIR POLLUTION CONTROL SYSTEM:
1. Details of Multi Cyclone Separator followed by Bag Filter attached to Existing Coal
fired 3 TPH Boiler:
Table 3: Specifications of Multi Cyclone Separator & Bag Filter
Particular Details
Capacity 3 tones/hr
Type of fuel used Lignite/steam coal
Quantity used 583 kgs/hr
ID fan cfm 6000
Size of MDC 1250 mm x 1250 mm x 2500 mm
MOC MS
Number of clones 20
Size of clones 150 x 80 NB
Gas volume 9350 m3/hr
Gas temperature 150 0C
Dust load 15 gms/m3
Particle size Above 5 microns
Filtration area 132 m2
Actual filter rate 1.18 m3/m
2/min
Pressure drop 150 mm Wg
Nos. of Bag filter 100 (Glass fibre)
Height of Chimney 31 meters
Dia of chimney 600 mm
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2. Details of Electro Static Precipitator to be attached to proposed coal fired 8 TPH Boiler:
Table 4: Specifications of Electro Static Precipitator
Particulars Details
ESP model SC-11-16-24(G) (3x9.125) 1.2 P
Design volume 18588 Am3/hr
Design Temperature 1500C
Maximum Inlet Dust Load 13.01 Gm/ Nm3
Outlet Emission 50 Mgm/ Nm3
Moisture in Gas 15.83% V/V
Collection area 1399 m2
Specific collection area 83.1 m2/m
3/s
No of gas passages 11
Velocity through ESP 0.49 M/s
No of fields 3
Migration velocity 5.37 Cm/s
Residence time 16.9 Sec
Dust collection efficiency 98.8%
(A) Primary Scrubber:
Table 5: Primary Scrubber
Scrubber Dia 450 mm
MOC MS/Graphite
Scrubber height 1930 mm
Overall height 2710 mm
Distributor 1
Type of packing Graphite
Blower 1000 cfm, 1.5 HP
Scrubbing liquid Water
Gas inlet 150 mm
Gas outlet 150 mm
Circulation pump capacity 5 m3/hr 5 HP
Circulation Tank capacity 5 m3
(B) Secondary Scrubber:
Table 6: Secondary Scrubber
Scrubber Dia 450 mm
MOC PP/FRP
Scrubber height 4350 mm
Overall height 5470 mm
Distributor 1
Type of packing 40 mm pp
Blower 1000 cfm, 1.5 HP
Scrubbing liquid 14% HCl
Gas inlet 100 mm
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Gas outlet 100 mm
Circulation pump capacity 3 m3/hr 3 HP
Circulation Tank capacity 3.5 m3
(C) Alkali Scrubber:
Table 7: Alkali Scrubber
Scrubber Dia 600 mm
MOC PP/FRP
Scrubber height 2300mm
Overall height 3930 mm
Distributor 1
Type of packing 40 mm pp
Blower 1000 cfm, 1.5 HP
Scrubbing liquid 5-7 % NaOH
Gas inlet 150 mm
Gas outlet 150 mm
Height of vent 11 meter
Circulation pump capacity 2m3/hr 2 HP
Circulation Tank capacity 1.5 m3
Figure 1: Flow Diagram of Scrubbing System for HCl, Cl2 & SO2 gas
Graphite
Falling Fluid
Absorbent
10 m2
PP FRP
Tank, 5000 lits
450 mm dia x
4000 mm ht.,
PP rashing
ring
PP FRP
Tank, 2000 lits
PP FRP
Tank, 2000 lits
300 mm dia x
4000 mm ht.,
PP rashing
ring
FLOW DIAGRAM OF SCRUBBING SYSTEM FOR HCL,CL2& SO2 GAS
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Annexure 12: Copy of CCA of Existing Plant
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Annexure 13: Copy of Environmental Clearance dated 23/10/2003
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Copy of Environmental Clearance dated 30/01/2009 (validity expired)
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