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PRE FEASIBILITY REPORT
FOR
EXPANSION OF EXISTING SYNTHETIC ORGANIC CHEMICALS MANUFACTURING UNIT
BALAJI AMINES LIMITED
At
Plot No: 4 & 5, Beside Sub-Station-II, I.D.A, Bollaram, Jinnaram (M),
Medak District, Telangana State - 502325
Contents
S. No. Description Page no. 1.0 Executive Summary 1 2.0 Introduction of The Project 2 2.1 Project Proponent. 2 2.2 Brief description of nature of the project. 2
2.3 Need for the project and its importance to the country and or region 2
2.4 Employment Generation(Direct and Indirect) due to the project 3
3.0 Project description 4 -6 3.1 Product and Production Capacity 7 3.2 Raw materials required and Quantities 7 3.3 Manufacturing Process 8 3.4 Resource – Utilize and Recycling 8
3.4.1 Water 8
3.4.2 Power Requirement 9 3.4.3 Fuel Requirement 9 3.5 Quantity of wastes to be generated 9
3.5.1 Waste Water Generation and utilization 9 3.5.2 Solid waste generation and Disposal 10
3.6 Schematic representations of the feasibility drawing which give information of EIA purpose. 10
4.0 Site Analysis 11 4.1 Connectivity 11 4.2 Land Form, Land use and Land ownership. 11 4.3 Existing Infrastructure 11 4.4 Soil classification 11 4.5 Climatic data from secondary sources. 12 4.6 Social Infrastructure available. 12 5.0 Planning brief 12 6.0 Proposed infrastructure 12 6.1 Industrial Area 12 6.2 Residential Area 12 6.3 Green Belt: 12 6.4 Social Infrastructure 12 6.5 Water management 13 6.6 Sewerage System 13
6.7 Industrial Waste Management 13 7.0 Rehabilitation and Resettlement (R&R) Plan 13 8.0 Project Schedule and Cost estimates 13 9.0 Analysis of project 14
LIST OF TABLES
Table No Description Page no. 2.1 Total Employment 3 3.1 Proposed Products and Quantities 7 3.2 Water Requirement Details 9 3.3 Wastewater generation and Treatment Method 9 3.4 Solid and hazardous waste generation and Disposal 10 8.1 Project Cost 13
LIST OF FIGURES
Figure No Description Page no. 1.1 Location Map 5 1.2 Google Earth Map Showing Balaji Amines Ltd 6
LIST OF FLOW CHART
Flow Chart No Description Page no.
3.1 Generalized Flow Chart for Synthetic organic chemicals Manufacturing
8
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 1
1.0 EXECUTIVE SUMMARY
M/s. BALAJI AMINES LTD.(BAL) is a limited company (the plant was originally in
the name of Bhagyanagar Chemicals Ltd., which is a WOS of BAL having lease
agreement) and commenced its commercial operations in 1994, Focusing its
attention on developing technology for import substitute products without any kind of
pollution, introduced quality products DMAHCL, TMAHCL other HCLs and natural
products such as Solonesol, 10 DAB etc.
S. No Parameter Description
1 Project Location Plot No: 4 & 5, Beside Sub-Station-II, I.D.A, Bollaram, Jinnaram (M), Medak District, Telangana State - 502325
2 Category of Project as per EIA Notification & Amendments
5 F(A)
3 Project cost 3.0 Crores
4 Plot area 4.2 Acres
5 Proposed Products List of products are Enclosed
6 Resources
(I)Electricity Requirement 600 HP
Source of electricity TSSPDCL
D. G. Sets Existing : 375 KVA Proposed : 360 KVA
(II)Water consumption 135 KLD
Source of water TSIIC Supply
Waste water generation 57.50 KLD
7 Solid waste generation
Organic Residue – 901 Kg/Day Inorganic solid waste – 38 Kg/Day MEE salts – 1375.00 Kg/Day Spent carbon – 16 Kg/Day Coal ash from Boiler – 7050 Kg/Day ETP Sludge – 30 Kg/Day Solvent Distillation bottom Residue – 43 Kg/Day
8 Nearest Highway NH 9 – 6.2 KMs 9 Nearest Railway Station Lingampally Railway Station - 7.7 Km
10 Nearest Air Port Rajiv Gandhi International Airport - 36.0 KM
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 2
2.0 INTRODUCTION OF THE PROJECT
The objective of this pre- feasibility study is to provide information for the expansion
of unit of M/s. Balaji Amines Ltd. Plot No: 4 & 5, Beside Sub-Station-II, I.D.A
Bollaram, Jinnaram (M),Medak District, Telangana State - 502325
2.1 Project Proponent Mr. B. Jogeshwar Rao is the Plant Manager and is Graduate ( B.Sc ) in Chemistry
from Nobel College, Machilipatnam (Andhra University). He has over 35 years of
experience in Plant Management, Including process optimization and Process Scale
up. He has handled projects dealing with organic and inorganic compounds. He has
worked with companies like Pure Drugs Pvt.Ltd. and Vanilin and Fine Chemicals Ltd.
and MCA Chemicals Ltd., and well acquainted with Operations of chemicals plants,
safety and environment culture and other legal requirements.
2.2 Brief description of nature of the project. M/s. Balaji Amines Ltd. commenced its commercial operations in 1994 and
manufactures DMAHCL and Natural Products such as Solonesol and 10 DAB etc. at
Plot No: 4 & 5, Beside Sub-Station-II, I.D.A, Bollaram, Jinnaram (M), Medak
District, Telangana State - 502325
2.3 Need for the project and its importance to the country and or region
We are the safest and largest manufacturer of DMAHCL products in India. The
market for DMAHCL and other products is increasing at the rate of 30% year on year
on volume basis. At present we only cater to Pharma sector. We are coming up with
highly efficient products that can cater to Healthcare industries. Hence a need is felt
to increase the present capacity of the plant and diversify to some of the new
generation products. The plant employs people from the local community. With
increase in plant capacity, the employment opportunity increases for the local
people. We are the only manufacturer of DMAHCL and other products in South India
and in future we intend to export this product to Global pharmaceutical industries.
With increase in volume the tax outgo to the govt will increase substantially.
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 3
2.4 Employment Generation (Direct and Indirect) due to the project
The unit has 20 permanent and 40 contractual employees. Apart from this there will
be significant indirect employment generation at the supplier firms and service
industry providing services to the company. Company shall be giving preference to
people from economically weaker sections for employment in various semi-
skilled/unskilled jobs thereby contributing to their upliftment. The details of total
employment in this unit shown in below Table 2.1.
TABLE 2.1: TOTAL EMPLOYMENT AFTER EXPANSION
Particulars No. of employees
Functional Area
Key managerial staff 10 Finance, Marketing, Production,
Quality control, R&D, Logistics etc.
Administration 5 Office work
Skilled and semi
skilled 80
Manufacturing, Maintenance, Stores
& Un skilled workers and contractors
Total 95
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 4
3.0 Project Description
M/s. Balaji Amines Limited was started in IDA, Bollaram of Telangana State in the
year 1994 to produce DMAHCL and other products and now proposing for expansion
of Existing Capacities with inclusion of new products apart from expanding DMAHCL
capacities as this product is mainly used in treating diabetes. As the incidence of
Diabetes has been growing rapidly, the capacity expansion is to meet the growing
demand. The process does not generate any effluent.
The Location map is shown at Figure -3.1 and Google earth map showing Balaji
Amines Ltd. plant is shown at Figure -3.2 .
The site central coordinates are Latitude : 17°32'54.20"N Longitude : 78°20'41.86"E
There are no archaeological, historical sites located nearby. Therefore, the project
site does not offer any negative impact on the local area, but rather has a positive
impact on socio economic conditions of the habitants around it.
The Balaji Amines Ltd. is 3 Km away from Nehru ORR and 6 Kms. from Lingampally
Railway Station.
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 5
FIGURE 3.1: LOCATION MAP
Balaji Amines Ltd. Plot No: 4 & 5, Beside Sub-Station-II, I.D.A, Bollaram, Jinnaram (M), Medak District, Telangana State - 502325
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 6
FIGURE 3.2: GOOGLE EARTH MAP SHOWING BALAJI AMINES LTD
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 7
3.1 Product and Production Capacity
M/s. Balaji Amines Ltd. is proposes to produce below mentioned products with
Manufacturing Capacity 1510 MT/Month and the list of product is shown in Table3.1.
Table3.1: Proposed Products and Quantity
S. No Product Name CAS No’s Quantity Kg/Month
1 16-Alpha hydroxyPrednisolone 13951-70-7 200.00
2 Beclomethasone Dipropionate 4419-39-0 200.00
3 Betamethasone 17-valerate 2152-44-5 500.00
4 Betamethasone Acetate 987-24-6 250.00
5 Betamethasone dipropionate 5593-20-4 500.00
6 Betamethasone Sodium Phosphate 151-73-5 250.00
7 Budesonide 51333-22-3 700.00
8 Ciclesonide 141845-82-1 1500.00
9 Dimethylamine Hydrochloride 506-59-2 12,00000.00
10 Emtricitabine 143491-57-0 600.00
11 Flumetasone Pivalate 2002-29-1 525.00
12 Fluticasone Furoate 397864-44-7 500.00
13 Lamivudine 134678-17-4 400.00
14 Mometasone Furoate 105102-22-5 500.00
15 Nadolol 42200-33-9 400.00
16 Povidone Iodine 25655-41-8 200000.00
17 PVP-A Copolymer Series 25086-89-9 50000.00
18 VP/DMAEMA Quaternized(PQ-11) 53633-54-8 50000.00
Total 1,507,025.00
3.2 Raw materials required and Quantities
All the raw materials required for manufacturing of above products will be sourced
from local/Non local market. The required raw materials and quantities are enclosed
as Annexure.
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 8
3.3 Manufacturing Process:
The manufacturing process of bulk drugs consists of chemical synthesis extending
to stages of processing involving different type of chemical reactions. The
generalized Flow chart for synthetic organic chemicals manufacturing is shown in
Flow chart 3.1. FLOW CHART 3.1: GENERALIZED FLOW CHART FOR SYNTHETIC ORGANIC
CHEMICALS MANUFACTURING
3.4 Resource – Utilize & Recycling
3.4.1 Water Water requirement of the project for domestic and industrial activity during operation
phase will be 135.00 KLD. The water requirement will be met through TSIIC supply.
The detailed water requirement shown in below Table 3.2.
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 9
Table 3.2: WATER REQUIREMENT DETAILS
S. No Purpose Water Requirement In KLD 1 Process 21.00 2 Washings 3.00 3 Boiler Make up 36.00 4 Cooling towers Make up 63.00 5 Scrubbing system 2.00 6 DM Plant 2.00 7 Domestic 4.00 8 Gardening 4.00
Total 135.00
3.4.2 Power Requirement Power requirement of proposed project will be made available through TSPCPDCL.
The total power requirement for the unit after expansion is 850 Hp respectively.
Proposing to Install 360 KVA DG set In addition to existing 375 KVA DG to meet the
emergency power requirement of the plant for the proposed Expansion.
3.5 Quantity of wastes to be generated 3.5.1 Waste Water Generation and utilization
Total effluent generated in the project is 57.50 KLD. The process waste water from
Process, floor Washes, scrubbers, QC and R&D are evaporated in MEE with stripper
and ATFD after neutralization. The condensate from MEE and ATFD will be
collected and treated in effluents treatment plant along with effluents from utilities
followed by RO. RO rejects will be send back to MEE and RO Permeate will be re-
used back.
To treat the sewage generated due to domestic activities will be disposed through
septic tank following by soak pit.
Table3.3: WASTEWATER GENERATION
S. No
Unit HTDS
In KLD
LTDS In
KLD
Effluent Generation
In KLD Method of Disposal
1 Process 18.00 11.00 29.00 HTDS Sent to stripper followed by MEE and ATFD. Condensate will be send to ETP followed by RO.
LTDS Effluents sent to ETP followed by
2 Washings 0.00 3.00 3.00
3 Boiler Make up 6.00 0.00 6.00
4 Cooling towers Make up
0.00 12.00 12.00
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 10
S. No
Unit HTDS
In KLD
LTDS In
KLD
Effluent Generation
In KLD Method of Disposal
5 Scrubbing system 2.00 0.00 2.00 RO system.RO Rejects sent to MEE system and RO Permeate to Reuse.
6 DM Plant 2.00 0.00 2.00
7 Domestic 0.00 3.50 3.50 Septic tank followed by soak pit
Total 28.00 29.50 57.50
3.5.2 Solid waste generation and Disposal
The following solid waste will be generated like Used drums & Tins, and Used Oil
etc.
The types of Hazardous and non Hazardous wastes generated from the project,
method of disposal is shown in below table-3.4.
Table 3.4: Solid & Hazardous waste generation and Disposal S.
No. Name of the Solid Waste Quantity In Kg/Day Disposal Method
1 Organic Residue 901.00 Sent to Cement Industries 2 Inorganic solid waste 38.00 Sent to TSDF 3 MEE salts 1375.00 Sent to TSDF 3 Spent carbon 16.00 Sent to Cement Industries 4 Coal ash from Boiler 7050.00 Sent to Brick manufacturers 5 ETP Sludge 30.00 Sent to TSDF
6 Solvent Distillation bottom Residue 43.00 Sent to Cement Industries
7 Used Oils & Grease 500 Ltrs/Annum
SPCB Authorized Agencies for Reprocessing/Recycling
8 Detoxified Containers, Liners Etc 1000 No’s/Month
After Detoxification sent back to suppliers/SPCB Authorized Parties
9 Used Lead Acid Batteries 2 No’s/Annum Send back to suppliers for buyback of New Batteries
3.6 Schematic representations of the feasibility drawing which give
information of EIA purpose.
The applicability of the S.O 1533 for the proposed project was explored by
considering different possibilities & provision made in the said notification.
Considering the products & project location of the proposed project it is noticed that
the proposed project falls under Category 5 (f) “A” of the Schedule-I of EIA
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 11
Notification SO 1533.
As per the provision of the SO 1533, it is necessary to get Environmental Clearance
by applying to MoEF along with the Environmental Impacts Assessment Study
Report for the proposed project prior to commissioning of the project activities.
Therefore the EIA is required to conduct to comply with provisions of SO 1533 made
for Category 5(f) “A” of schedule –I of the notification.
4.0 Site Analysis
4.1 Connectivity
Balaji Amines Ltd. is located at Plot No: 4 & 5, Beside Sub-Station-II, I.D.A,
Bollaram, Jinnaram (M), Medak District, Telangana State - 502325
The nearest habitation from the site is Bollaram at a distance of 0.5 Km (N).
The nearest railway station is Lingampally Railway Station at a distance of 7.7
KMs from the site (SSW).
The nearest airport is Rajiv Gandhi International Airport at a distance of 36.00
KM.
The Nearest road ways NH 9 – 6.2 Km.
4.2 Land Form, Land use and Land ownership. Balaji Amines Ltd is an existing unit. There would be no any change in Land Use,
Land Cover or Topography of plot. Green belt is already developed in the plant
premises.
4.3 Existing Infrastructure. Project is a located very nearer to Nehru ORR Highway ( NH-2 KM) and the city is
located (i.e Hyderabad -12.0 Kms) and the basic infrastructure is already there. The
plant is well connected with Road and Railway facilities
4.4 Soil classification
The district is mainly covered by two types of soils i.e black and chalka (Sandy
looms) covering 55% and 45% respectively of the total area.
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 12
4.5 Climatic data from secondary sources.
Temperature Maximum: 42.20o C Minimum: 10.0 o C
Normal annual rainfall 811.9mm
4.6 Social Infrastructure available.
Well developed social infrastructure facilities are available at nearby Habitations. 5.0 Planning Brief
Proposed expansion activities will be started after getting statutory clearance form
related authorities. The project will be completed within two years.
Further project activities will take care of all the rules and regulation of statutory
authority and provide the control measure and devices to achieve the standard
norms.
6.0 Proposed Infrastructure
6.1 Industrial Area
The infrastructure and other facilities are already well developed in nearby Mandal
head quarter and other villages.
6.2 Residential Area
The employees who will work in the industry will be living in nearby Bollaram or
Hyderabad & there no proposal for creating residential area for employees.
6.3 Green Belt: 33 % of Green Belt will be developed and it will be maintained. 6.4 Social Infrastructure: Facilities like road and communication are good; Banks, ATM's and medical facilities are also adequate in the area. Amenities: Education- schools including middle, secondary and higher secondary schools,
social welfare hostels are available and technical education colleges are plenty in the
nearby areas.
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 13
Medical and Health- Community Health Centre, & Primary Health center Are available near village and also there is a ESI dispensary in Bollaram Village. Power and water- All the villages are electrified and drinking water facilities are extended to all villages. Rail and Road- The project site is very well connected by road through Nehru ORR, South Central railways etc.
6.5 Water management
Water requirement will be met through IDA Supply. 6.6 Sewerage System:
Domestic waste water will be disposed off through soak pit system.
6.7 Industrial Waste Management: The Hazardous waste sent to TSDF.
7.0 Rehabilitation and Resettlement (R & R) Plan
Rehabilitation & Resettlement (R&R) plan is not applicable to proposed project.
8.0 Project Schedule & Cost Estimates
Expansion activities will be started after getting statutory clearance from concerned
authorities. The project will be completed within two years.
This Expansion will provide benefits to the local people in terms of sustainable
development in terms of economical and social welfare.
The project cost for proposed Project is 3.00 Crores will be used for constructing
additional building, Equipments, Machinery, ZLD System and Air pollution control
Equipments.
TABLE 8.1: PROJECT COST
S. No Particulars Rs. Crores
1 Land 0
3 Plant & Machinery 2.50
4 Working Capital Margin 0.50
Total 2.50
PRE FEASIBILITY REPORT
M/s. Balaji Amines Ltd. Page 14
9.0 Analysis of proposal (Final Recommendations)
Local people will get direct employment. which will in turn develop all the
stakeholders.
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 areas under CSR activities.