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M/s. ALLCHEM LABORATORIES BLOCK NO. 1088/B/P, 1088/A, LAMDAPURA ROAD, VILLAGE MANJUSAR, TALUKA SAVLI – 391 775, DIST. VADODARA (GUJ)
ENVIRONMENTAL IMPACT AND RISK ASSESSMENT REPORT FOR PROPOSED EXPANSION OF EXISTING ADVANCE PHARMACEUTICAL INTERMEDIATE PRODUCTS MANUFACTURING UNIT
Winter ‐ 2011
NABL Accredited Testing Laboratory ISO 9001:2008 Certified Company
Aqua‐Air Environmental Engineers P. Ltd. 403, Centre Point, Nr. Kadiwala School, Ring Road, Surat ‐ 395002
Applied to QCI dated 08/04/2010 & Applicant No. 55 (Ref.: www.qcin.org/nabet/consapplorg.php#)
ENVIRONMENTAL IMPACT AND RISK ASSESSMENT REPORT
CLIENT
PROJECT TITLE
PROJECT NO.
:
:
:
M/s. ALLCHEM LABORATORIES
BLOCK NO. 1088/B/P, 1088/A,
LAMDAPURA ROAD, VILLAGE MANJUSAR,
TALUKA SAVLI – 391 775, DIST. VADODARA (GUJ)
ENVIRONMENTAL IMPACT AND RISK ASSESSMENT REPORT
FOR PROPOSED EXPANSION OF EXISTING ADVANCE
PHARMACEUTICAL INTERMEDIATE PRODUCTS
MANUFACTURING UNIT
389000
** PREPARED BY **
NABL Accredited Testing Laboratory
An ISO 9001:2008 Certified Company
Aqua‐Air Environmental Engineers P. Ltd.
(Pollution Control Consultants & Engineers)
403, Centre Point, Nr. Kadiwala School, Ring Road, Surat – 395002 (Guj)
Tel: +91 (261) 2460854/2461241/3048586 Fax: +91 (261) 2707273/3987273
e‐mail: [email protected] website: www.aqua‐air.co.in
INDEX
SR. NO. TITLE PAGE NO.
1 CHAPTER 1: INTRODUCTION
1.1 INTRODUCTION 1‐1
1.1.1 PROMOTERS& THEIR BACKGROUND 1‐1
1.1.2 JUSTIFICATION OF PROJECT 1‐6
1.2 PROJECT DETAILS 1‐7
1.2.1 REGULATORY FRAMEWORK 1‐11
1.3 PROJECT SETTING 1‐12
1.3.1 LOCATION 1‐12
1.3.2 KEY INFRASTRUCTURAL FEATURES AND SETTLEMENTS 1‐16
1.3.2.1 METHOD OF DATA PREPARATION 1‐16
1.3.2.2 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT
SITE
1‐16
1.3.2.3 MAP OF KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS 1‐17
1.4 PURPOSE OF EIA 1‐20
1.5 OBJECTIVES OF EIA 1‐20
1.6 METHODOLOGY FOR EIA 1‐20
1.6.1 BASE LINE ENVIRONMENTAL CONDITION 1‐20
1.6.1.1 AMBIENT AIR ENVIRONMENT 1‐20
1.6.1.2 GROUND AND SURFACE WATER ENVIRONMENT 1‐21
1.6.1.3 NOISE ENVIRONMENT 1‐21
1.6.1.4 SOIL ENVIRONMENT 1‐21
1.6.1.5 BIOLOGICAL ENVIRONMENT 1‐22
1.6.1.6 SOCIO‐ECONOMIC ENVIRONMENT 1‐22
1.6.2 IDENTIFICATION OF POLLUTION SOURCE 1‐22
1.6.3 EVALUATION OF POLLUTION CONTROL AND ENVIRONMENTAL
MANAGEMENT SYSTEM
1‐22
1.6.4 EVALUATION OF IMPACT 1‐22
1.6.5 PREPARATION OF ENVIRONMENTAL MANAGEMENT PLAN 1‐22
1.7 STRUCTURE OF REPORT 1‐23
2 CHAPTER 2: PROJECT DESCRIPTION AND INFRASTRUCTURAL FACILITIES
2.1 BACKGROUND 2‐1
2.2 PROJECT COST 2‐1
2.3 MAIN PHASES OF THE PROJECT 2‐2
2.3.1 PRE CONSTRUCTION ACTIVITIES 2‐2
2.3.2 CONSTRUCTION ACTIVITIES 2‐2
2.3.3 MANUFACTURING ACTIVITIES 2‐3 to 2‐44
2.4 RAW MATERIAL CONSUMPTION, STORAGE AND HANDLING 2‐45
2.4.1 DETAILS OF SOLVENT RECOVERY PLAN 2‐49
2.5 INFRASTRUCTURE FACILITIES 2‐53
2.5.1 LAND 2‐53
2.5.2 TRANSPORTATION FACILITIES 2‐54
2.5.3 WATER AND WASTEWATER 2‐54
2.5.3.1 TREATMENT PROCESS 2‐58
2.5.3.2 REVERSE OSMOSIS (RO) SYSTEM 2‐64
2.5.4 DETAILS OF UTILITIES 2‐71
2.5.5 ELECTRICITY REQUIREMENT 2‐72
2.6 POLLUTION POTENTIAL AND ITS CONTROL MEASURE 2‐72
2.6.1 AIR POLLUTION AND CONTROL SYSTEM 2‐72
2.6.1.1 BOILER DETAIL 2‐73
2.6.1.2 SCRUBBER SYSTEM 2‐74
2.6.2 NOISE LEVEL AND CONTROL SYSTEM 2‐78
2.6.3 HAZARDOUS AND SOILD WASTE GENERATIONS AND DISPOSAL SYSTEM 2‐78
2.6.4 DETAILS OF GREENBELT 2‐81
3 CHAPTER 3: BASELINE ENVIRONMENTAL STATUS
3.1 ESTABLISHMENT OF IMPACT ZONE 3‐2
3.2 METEOROLOGY 3‐3
3.3 MICRO‐METEOROLOGY OF THE AREA 3‐3
3.3.1 TEMPERATURE DETAILS 3‐4
3.3.2 RELATIVE HUMIDITY (RH) 3‐5
3.3.3 RAINFALL 3‐6
3.3.4 WIND SPEED 3‐7
3.4 AIR ENVIRONMENT 3‐11
3.4.1 DESIGN OF NETWORK FOR AMBIENT AIR QUALITY MONITORING
LOCATIONS
3‐11
3.4.2 RECONNAISSANCE 3‐11
3.4.3 METHODOLOGY FOR AMBIENT AIR QUALITY MONITORING 3‐12
3.5 NOISE ENVIRONMENT 3‐19
3.5.1 METHODOLOGY FOR NOISE MONITORING 3‐19
3.5.2 NOISE LEVELS DUE TO TRANSPORTATION 3‐22
3.6 WATER ENVIRONMENT 3‐24
3.6.1 RECONNAISSANCE 3‐24
3.6.2 METHODOLOGY FOR WATER QUALITY MONITORING 3‐25
3.7 LAND ENVIRONMENT 3‐31
3.7.1 METHODOLOGY FOR SOIL MONITORING 3‐31
3.7.3 SOIL CLASSIFICATIONS 3‐35
3.7.3.1 METHOD OF PREPARATION 3‐35
3.7.3.2 DESCRIPTION OF SOIL CHARACTERISTICS AND AREA UNDER DIFFERENT
SOIL TYPES
3‐35
3.7.3.3 SOIL CHARACTERISTICS MAP 3‐35
3.8 GEOLOGICAL DATA 3‐38
3.8.1 METHOD OF PREPARATION 3‐38
3.8.2 DESCRIPTION OF GEOLOGICAL CLASSIFICATION AND AREA UNDER
DIFFERENT FORMATIONS
3‐38
3.7.3 GEOLOGICAL MAP 3‐38
4 CHAPTER 4: LAND USE PATTERN, BIOLOGICAL ENVIRONMENT & SOCIO ‐ ECONOMIC
ENVIRONMENT
4.1 LAND USE PATTERN 4‐1
4.1.1 METHOD OF DATA PREPARATION 4‐1
4.1.2 AREA UNDER DIFFERENT LANDUSE 4‐2
4.2 ECOLOGICAL INFORMATION 4‐4
4.2.1 INTRODUCTION 4‐4
4.2.2 VEGETATION COVER AND FOREST BOUNDARIES WITHIN VADODARA
DISTRICT
4‐4
4.2.2.1 AREA UNDER FORESTS AND SANCTUARY 4‐5
4.2.3 FLORA 4‐6
4.2.4 FAUNA 4‐7
4.2.5 GROUND WATER HYDROLOGY 4‐8
4.3 SOCIO‐ECONOMIC ENVIRONMENT 4‐10
4.3.1 SETTLEMENTS AND DEMOGRAPHIC PATTERN 4‐10
4.3.1.1 METHOD OF DATA PREPARATION 4‐10
4.3.1.2 DEMOGRAPHIC DATA WITHIN THE REGION 4‐10
4.3.1.3 LITERACY RATE 4‐14
4.3.2 OCCUPATIONAL STRUCTURE 4‐16
4.3.3 LAND USE AND LAND COVER WITH TOWNS AND VILLAGE LOCATIONS 4‐18
4.3.4 AMENITIES 4‐20
5 CHAPTER 5: IDENTIFICATION AND ASSESSMENT OF IMPACTS
5.1 IDENTIFICATION OF IMPACTS 5‐1
5.2 EVALUATION AND PREDICTION OF IMPACTS 5‐8
5.2.1 WATER ENVIRONMENT 5‐10
5.2.1.1 CONSTRUCTION PHASE IMPACTS 5‐10
5.2.1.2 OPERATION PHASE IMPACTS 5‐11
5.2.1.3 MITIGATION MEASURES 5‐11
5.2.2 AIR ENVIRONMENT 5‐12
5.2.2.1 CONSTRUCTION PHASE IMPACTS 5‐13
5.2.2.2 OPERATION PHASE IMPACTS 5‐13
5.2.2.2 MITIGATION MEASURES 5‐13
5.2.3 NOISE ENVIRONMENT 5‐26
5.2.3.1 CONSTRUCTION PHASE IMPACTS 5‐26
5.2.3.2 OPERATION PHASE IMPACTS 5‐26
5.2.4 LAND USE AND SOIL QUALITY 5‐27
5.2.4.1 CONSTRUCTION PHASE IMPACTS 5‐27
5.2.4.2 OPERATION PHASE IMPACTS 5‐27
5.2.4.3 MITIGATION MEASURES 5‐27
5.2.4.4 DETAILS OF HAZARDOUS WASTE GENERATION 5‐28
5.2.4.5 TRANSPORTATION OF HAZARDOUS WASTE 5‐28
5.2.4.6 DISPOSAL OF HAZARDOUS WASTE 5‐29
5.2.5 HOUSING 5‐29
5.2.6 INFRASTRUCTURE AND SERVICES 5‐29
5.2.7 ENVIRONMENTAL HAZARDS 5‐30
5.2.8 ECOLOGY 5‐30
5.2.8.1 NATURAL VEGETATON 5‐31
5.2.8.2 CROPS 5‐31
5.2.8.3 FOREST AND SPECIES DIVERSITY 5‐31
5.2.8.4 FISHERIES & AQUATIC LIFE 5‐31
5.2.8.5 AESTHETIC ENVIRONMENT 5‐32
5.2.8.6 DEMOGRAPHY, ECONOMICS, SOCIOLOGY & HUMAN SETTLEMENT 5‐32
5.2.8.7 SOCIO ‐ ECONOMIC IMPACTS 5‐32
5.3 MATRIX REPRESENTATION 5‐34
5.3.1 CUMULATIVE IMPACT CHART 5‐34
6 CHAPTER 6: ENVIRONMENTAL MANAGEMENT PLAN
6.1 BACKGROUND 6‐1
6.2 OBJECTIVES OF ENVIRONMENTAL MANAGEMENT PLAN 6‐1
6.3 ENVIRONMENTAL MANAGEMENT CELL 6‐2
6.4 ENVIRONMENTAL MANAGEMENT PLAN 6‐4
6.4.1 PROJECT ENVIRONMENT MONITORING PLAN 6‐5
6.4.2 CONSTRUCTION PHASE MANAGEMENT 6‐7
6.4.3 OPERATIONAL PHASE MANAGEMENT 6‐8
6.4.3.1 WATER ENVIRONMENT 6‐8
6.4.3.2 AIR ENVIRONMENT 6‐9
6.4.3.3 NOISE ENVIRONMENT 6‐9
6.4.3.4 LAND ENVIRONMENT 6‐10
6.4.3.5 GREEN BELT DEVELOPMENT 6‐11
6.4.3.6 HEALTH AND SAFETY 6‐13
6.4.3.7 INFORMATION FOR CONTROL OF FUGITIVE EMISSIONS 6‐13
6.4.3.8 INFORMATION FOR RAIN WATER HARVESTING 6‐14
6.4.3.9 MEASURES FOR CONSERVATION OF ENERGY 6‐17
6.4.3.10 ODOR MANAGEMENT PLAN 6‐17
6.5 SOCIO ECONOMIC DEVELOPMENT ACTIVITIES 6‐19
6.6 CAPITALS AND O&M COST FOR ENVIRONMENTAL MANGEMENT 6‐19
7 CHAPTER 7: RISK ANALYSIS & DISASTER MANAGEMENT PLAN
7.1 BACKGROUND 7‐1
7.2 STORAGE AND HANDLING OF HAZARDOUS CHEMICALS 7‐1
7.2.1 HAZARD AND CONTROL 7‐5 to 7‐38
7.3 HEALTH & SAFETY MEASURES 7‐38
7.3.1 OCCUPATIONAL HEALTH SCHEME FOR THE WORKERS 7‐39
7.3.2 TRAINING AND EDUCATION OF EMPLOYEES AND PERSONAL PROTECTIVE
EQUIPMENTS
7‐40
7.4 FIRE FIGHTING SYSTEM 7‐41
7.5 MAJOR HAZARDS AND DAMAGE CRITERIA 7‐41
7.6 HAZARD IDENTIFICATION 7‐43
7.7 CONSEQUENCE ANALYSIS 7‐44
7.7.1 DAMAGE CRITERIA 7‐45
7.7.2 MAXIMUM CREDIBLE LOSS ACCIDENT SCENARIOS 7‐50
7.7.3 CONSEQUENCE ANALYSIS CALCULATIONS 7‐51
7.7.4 SCENARIOS 7‐54
7.8 DETAILED SUMMARY OF RESULTS: 7‐55
7.8.1 SCENARIO # 1: RELEASE OF TOLUENE 7‐55
7.8.2 SCENARIO # 2: RELEASE OF IPA 7‐62
7.8.3 SCENARIO # 3: RELEASE OF AMMONIA 7‐67
7.8.4 SCENARIO # 4: RELEASE OF BROMINE 7‐73
7.8.5 SCENARIO # 5: RELEASE OF HCl (30 %) 7‐78
7.8.6 SCENARIO # 5: RELEASE OF DICHLOROMETHANE 7‐83
7.8.7 SCENARIO # 5: RELEASE OF ETHYL ACETATE 7‐89
7.8.8 SCENARIO # 5: RELEASE OF METHANOL 7‐94
7.8.9 SCENARIO # 5: RELEASE OF PHOSPHORUS OXYCHLORIDE 7‐101
7.8.9 SCENARIO # 5: RELEASE OF THIONYL CHLORIDE 7‐107
7.9 DISASTER MANAGEMENT PLAN 7‐113
7.9.1 DEFINING THE NATURE OF EMERGENCY 7‐113
7.9.2 OBSERVER 7‐113
7.9.3 STRUCTURE OF EMERGENCY MANAGEMENT 7‐114
7.9.3.1 CHIEF EMERGENCY CONTROLLER 7‐114
7.9.3.2 INCIDENT CONTROLLER 7‐115
7.9.3.3 SITE MAIN CONTROLLER 7‐117
7.9.3.4 KEY PERSONNELS 7‐118
7.9.3.5 ESSENTIAL WORKERS 7‐119
7.9.3.6 ASSEMABLY POINT 7‐120
7.9.3.7 EMERGENCY CONTROL CENTER 7‐122
7.9.3.8 FIRE CONTROL ARRANGEMENTS 7‐122
7.9.3.9 MEDICAL SERVICES 7‐123
7.10 COMMMUNICATION SYSTEM 7‐123
7.10.1 RAISING THE ALARM 7‐124
7.10.2 DECLARING THE MAJOR EMERGENCY 7‐124
7.10.3 TELEPHONE MESSAGES 7‐124
7.10.4 COMMUNICATION OF EMERGENCY 7‐124
7.11 SAFETY INCHARGE 7‐129
7.11.1 ROLE OF SR. SECURITY OFFICER AND SECURITY SUPERVISORS 7‐129
7.11.2 ROLE OF SECURITY GUARD 7‐130
7.11.3 MAINTENANCE SERVICES 7‐131
7.11.4 ROLE OF ELECTRICAL DEPARTMENT 7‐131
7.11.5 ROLE OF INSTRUMENT DEPARTMENT 7‐132
7.12 OFF – SITE EMERGENCY PLAN 7‐132
7.12.1 NEED OF THE OFF – SITE EMERGENCY PLAN 7‐132
7.12.2 ROLE OF FACTORY MANAGEMENT 7‐134
7.12.3 ROLE OF EMERGENCY CO‐ORDINATION OFFICER (ECO) 7‐134
7.12.4 ROLE OF THE FIRE AUTHORITIES 7‐134
7.12.5 ROLE OF THE HEALTH AUTHORITIES 7‐136
7.12.6 ROLE OF TELEPHONE DEPARTMENT 7‐135
7.13 TRAINING, REHERASAL & RECORDS 7‐135
7.13.1 NEED OF TRAINNING & REHEARASAL 7‐135
7.13.2 SOME CHECK POINTS 7‐136
7.13.3 RECORDS AND UPDATING THE PLAN 7‐137
LIST OF TABLES
TABLE
NO.
TITLE PAGE NO.
1.1 LIST OF PRODUCTS ALONGWITH PRODUCTION CAPACITY (EXISTING &
PROPOSED)
1‐8 TO 1‐11
1.2 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT
SITE
1‐16
2.1 BREAK UP OF PROPOSED INVESTMENT & MEANS OF FINANCE 2‐1 to 2‐2
2.2 RAW MATERIAL REQUIREMENT (EXISTING & PROPOSED ) 2‐45 to 2‐49
2.3 LIST OF SOLVENTS ALONGWITH TOTAL RECOVERY 2‐52
2.4 LAND BREAK‐UP OF THE PLANT 2‐53
2.5 WATER CONSUMPTION & WASTE WATER GENERATION (EXISTING &
PROPOSED SCENARIO)
2‐55
2.6 LIST OF ETP UNITS (EXISTING) 2‐59
2.7 LIST OF ETP UNITS (PROPOSED) 2‐62
2.8 THE DETAILS OF UTILITIES 2‐71
2.9 THE DETAILS OF SOURCE OF EMISSION & CONTROL MEASURES 2‐72
2.10 HAZARDOUS & SOILD WASTE GENERATION QUANTITY, PHYSICAL
CHARACTERISTICS AND MODE OF DISPOSAL
2‐79 to 2‐80
3.1 TEMPERATURE DETAILS 3‐4
3.2 RELATIVE HUMIDITY DETAILS 3‐5
3.3 RAINFALL DETAILS 3‐6
3.4 WIND SPEED DETAILS 3‐7
3.5 SITE SPECIFIC METEOROLOGICAL DATA 3‐8
3.6 DETAILS OF AMBIENT AIR QUALITY MONITORING LOCATIONS 3‐13
3.7 AMBIENT AIR QUALITY STATUS 3‐15 to 3‐18
3.8A DETAILS OF AMBIENT NOISE QUALITY MONITORING LOCATIONS 3‐20
3.8B BACKGROUND NOISE LEVELS 3‐22
3.9 NOISE LEVELS DUE TO TRANSPORTATION 3‐24
3.10 SAMPLING LOCATIONS FOR MONITORING SURFACE WATER AND GROUND
WATER QUALITY
3‐25
3.11 WATER QUALITY‐ PHYSICAL PARAMETERS 3‐27 to 3‐30
3.12 SAMPLING LOCATIONS: SOIL QUALITY 3‐31
3.13 PHYSICO‐CHEMICAL CHARACTERISTICS OF SOIL 3‐33 to 3‐34
3.14 SOIL CHARACTERISTICS UNDER PROJECT AREA 3‐36
3.15 GEOLOGICAL FEATURES 3‐38
4.1 AREAS UNDER DIFFERENT LANDUSE 4‐2
4.2 DETAILS OF FOREST COVER OF VADODARA DISTRICT 4‐4
4.3 FLORA 4‐6
4.4 FAUNA 4‐7
4.5 DEMOGRAPHIC DATA (CENSUS‐2001) 4‐11
4.6 POPULATION DENSITY 4‐12
4.7 LITERACY RATE 4‐14
4.8 OCCUPATIONAL STRUCTURE 4‐16 TO 4‐
17
4.9 DETAILS OF AMENITIES AVAILABLE IN THE STUDY AREA 4‐21 to 4‐23
5.1 CHARACTERISTICS OF EFFLUENT (EXISTING) 5‐12
5.2 DETAILS OF EMISSION FROM STACKS (PROPOSED) 5‐16
5.3 SUMMERY OF ISCST3 MODEL OUTPUT FOR SPM, SO2, NOx , HCl, AMMONIA,
Cl2 and HBr
5‐24
5.4 PREDICTED AMBIENT AIR QUALITY FOR SPM, SO2, NOX, HCL & Cl2 5‐25
5.5 NOISE LEVELS AT DIFFERENT LOCATIONS WITHIN INDUSTRY 5‐26
5.6 IMPACT IDENTIFICATION MATRIX 5‐35 & 5‐36
5.7 POTENTIAL IMPACTS & MITIGATIVE MEASURES 5‐37
5.8 ENVIRONMENTAL IMPACT MATRIX 5‐38
5.9 CUMULATIVE IMPACT CHART 5‐39
6.1 ENVIRONMENT MANAGEMENT PLAN 6‐4
6.2 PROJECT ENVIRONMENT MONITORING PLAN 6‐5 to 6‐7
6.3 GREEN BELT DEVELOPMENT PLAN & SPECIES AS GREENBELT 6‐12 to 6‐13
7.1 STORAGE DETAILS OF HAZARDOUS CHEMICALS 7‐2 to 7‐4
7.2 ENVIRONMENT ASPECTS, IMPACT, RATINGS AND CONTROL MEASURES 7‐11 to 7‐37
7.3 DETAILS OF FIRE AND SAFETY EQUIPMENT 7‐41
7.4 POSSIBLE ACCIDENT SCENARIOS AT M/S. ALLCHEM LABORATORIES 7‐54
7.5 EMERGENCY CONTACT TELEPHONE NUMBERS (ON SITE EMERGENCY) 7‐126
7.6 A FORM TO RECORD EMERGENCY TELEPHONE CALL 7‐129
LIST OF FIGURES
FIGURE
NO.
TITLE PAGE NO.
1.1 STUDY AREA 1‐13
1.2 LAYOUT OF THE PLANT 1‐14
1.3 MAP TO DISTANCES OF CRITICALLY/SEVERELY POLLUTED AREA FROM THE
PROJECT SITE (GOOGLE MAP)
1‐15
1.4 KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS 1‐18
1.5 SATELLITE IMAGERY ALONG WITH PRESENT LAND USE PATTERN 1‐19
1.6 EIA PLAN & PROCEDURE 1‐25
2.1 WATER BALANCE DIAGRAM (EXISTING AND TOTAL AFTER PROPOSED
EXPANSION)
2‐56 TO 2‐
57
2.2 FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT (EXISTING) 2‐60
2.3 FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT (PROPOSED) 2‐63
2.4 FLOW DIAGRAM OF RO PLANT 2‐70
2.5 SCRUBBER SYSTEM‐I, II & III 2‐75 to 2‐77
3.1 WIND ROSE DIAGRAM & STABILITY CLASS DISTRIBUTION 3‐9 to 3‐10
3.2 LOCATION OF AMBIENT AIR QUALITY MONITORING STATIONS 3‐14
3.3 LOCATION OF NOISE LEVEL MONITORING STATIONS 3‐21
3.4 LOCATION OF NOISE LEVEL MONITORING STATIONS (TRANSPORTATION) 3‐23
3.5 LOCATIONS OF WATER SAMPLING STATIONS 3‐26
3.6 LOCATIONS OF SOIL SAMPLING STATIONS 3‐32
3.7 SOIL CHARACTERISTICS MAP 3‐37
3.8 MAJOR GEOLOGICAL FEATURES 3‐39
4.1 LAND USE/ LAND COVER 4‐3
4.2 GRAPHICAL REPRESENTATION OF FOREST COVER OF VADODARA DISTRICT 4‐5
4.3 HYDROLOGY 4‐9
4.4 DETAILS OF SEX RATIO & POPULATION DENSITY 4‐13
4.5 LITERACY RATE 4‐15
4.6 LANDUSE/ LANDCOVER WITH VILLAGE LOCATIONS 4‐19
5.1 IMPACT NETWORK ON AIR, NOISE, WATER, SOCIO‐ECONOMIC AND
CULTURAL AND LAND ENVIRONMENTS
5‐2 to 5‐7
5.2 EQUAL CONCENTRATION CONTOUR PLOT FOR SPM, SO2, NOx , HCl, 5‐17 to 5‐23
AMMONIA, Cl2 and HBr
6.1 ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL 6‐3
6.2 LOCATION OF BORE WELL FOR RAINWATER HARVESTING 6‐16
7.1 LAYOUT & GRAPHS FOR SCENARIO # 1 7‐57 to 7‐61
7.2 LAYOUT & GRAPHS FOR SCENARIO # 2 7‐63 to 66
7.3 LAYOUT & GRAPHS FOR SCENARIO # 3 7‐69 to 7‐72
7.4 LAYOUT & GRAPHS FOR SCENARIO # 4 7‐74 to 7‐77
7.5 LAYOUT & GRAPHS FOR SCENARIO # 5 7‐79 to 7‐82
7.6 LAYOUT & GRAPHS FOR SCENARIO # 6 7‐84 to 7‐88
7.7 LAYOUT & GRAPHS FOR SCENARIO # 7 7‐90 to 7‐93
7.8 LAYOUT & GRAPHS FOR SCENARIO # 8 7‐96 to 7‐
100
7.9 LAYOUT & GRAPHS FOR SCENARIO # 9 7‐103 to 7‐106
7.10 LAYOUT & GRAPHS FOR SCENARIO # 10 7‐109 to 7‐112
7.11 LOCATION OF ASSEMBLY POINT 7‐121
CONSULTANTS ENGAGED M/s. Allchem Laboratories proposes to expand manufacturing activities by introduction of
new products at existing unit. Since this proposed project activity require Environmental
Impact Assessment Studies and Environmental Clearance, the Company has entrusted M/s.
Aqua‐Air Environmental Engineers Pvt. Ltd., Surat for carrying out the EIA Studies as per the
prevailing rules and regulations.
Company has applied for Environmental Clearance to Ministry of Environment & Forests.
TORs Presentation to Expert Appraisal Committee of MoEF was done on December 23, 2011.
TORs has been finalized in the meeting, including certain additional points. M/s. Aqua‐Air
Environmental Engineers Pvt. Ltd. has carried out EIA Studies as per TOR and guidelines of
EAC, MoEF, New Delhi.
COPY OF TORs FROM EAC (NEW DELHI)
COMPLIENCE OF ADDITIONAL TERMS OF REFERENCES (TORs)
SR.
NO.
TERMS OF REFERENCES COMPLIENCE
1 Executive Summery of the Project. Please Refer Annexure‐7. Page No. A‐11.
2 Justification of the Project. Please Refer Chapter‐1, Section‐1.1.2, Page
No. 1‐6 to 1‐7.
3 Promoters and their back ground. Please Refer Chapter‐1, Section‐1.1.1, Page
No. 1‐1 to 1.6.
4 Regulatory framework. Please Refer Chapter‐1, Section‐1.2.1, Page
No. 1‐11.
5 A map indicating location of the project and
distance from severely polluted area.
Please Refer Chapter‐1, Figure‐1.3, Page No.
1‐15.
6 Project location and Plant Layout. Project Location: 22° 26' 45.178656" North
latitude and 73° 11' 5.395236" East
longitude. Please Refer Chapter‐1, Figure‐
1.1 and 1.4, Page No. 1‐13 and 1‐18
respectively.
For Plant Layout, Chapter‐1, Figure‐1.2, Page
No. 1‐14.
7 Infrastructure facilities including power
sources.
Please Refer Chapter‐2, Section‐2.5, Page
No. 2‐53 to 2‐72.
8 Total cost of the project along with total
capital cost and recurring cost/annum for
environmental protection measures.
Please Refer Chapter‐6, Section‐6.6, Page
No. 6‐19.
9 Project site location along with site map of 10
km area and site details providing various
industries, surface water bodies, forests etc.
Please Refer Chapter‐1, Figure‐1.4, Page No.
1‐18.
10 Present land use based on satellite imagery
for the study area of 10 km radius.
Please Refer Chapter‐1, Figure‐1.5, Page No.
1‐19.
11 Location of National Park/Wild life There is no National Park/Wild life
sanctuary/Reserve Forest within 10 km radius
of the project.
sanctuary/Reserve Forest falls within 10 Km
radial distance from the project site.
12 Details of the total land and break‐up of the
land use for green belt and other uses.
Please Refer Chapter‐2, Section‐2.5.1, Table‐
2.4, Page No. 2‐53 to 2‐54.
13 Environment clearance for the existing unit
issued by the Ministry (reasons, if not
obtained). Consent to Operate and
Authorization accorded by the GPCB along
with point‐wise compliance report.
The existing products manufacturing by M/s.
Allchem Laboratories did not fall under Old
EIA Notification, 1994 so that we have
obtained NOC for the same from GPCB in
the year 2004, please refer Annexure‐8.
Page No. A‐17.
For consent to operate and authorization
accorded by GPCB and its point‐wise
compliance report please refer Annexure‐9
and Annexure‐10 respectively. Page No. A‐
29 and A‐35 respectively.
14 List of products alongwith the production
capacities and list of solvents and its recovery
plan.
For products list; Please Refer Chapter‐1,
Table‐1.1, Page No. 1‐8 to 1‐11.
For Solvents list and its recovery plan: Please
Refer Chapter‐2, Section‐2.4.1, Table‐2.3,
Page No. 2‐49 to 2‐52.
15 Detailed list of raw material required and
source, mode of storage and transportation.
For raw material list; Please Refer Chapter‐2,
Section‐2.4, Table‐2.2, Page No. 2‐45 to 2‐
49.
The raw materials are procured from
nearest sources as much as possible from
Indian market.
The raw materials are received in tanks,
HDPE/fibre drums, HMHDPE Carboys and
cylinders as well as through tankers and
stored at ambient temperature. All the
storage tanks of hazardous flammable
substances are located within premises in
separate storage area i.e. solvent farm area
at ambient temperature. Solvent like
Methanol, Toluene, IPA, Xylene, etc. shall be
stored in underground MS/SS tank with all
precautionary process instrumentation and
safety appliances.
Large area shall be covered by well‐designed
warehouse, which is containing store office,
raw material store, finished product store,
etc.
Transportation of all the raw material and
products are primarily by road only.
The above procedures will remain same
after proposed expansion.
16 Details of the existing Sulphonation plant. NA
17 Manufacturing process details alongwith the
chemical reactions and process flow chart.
Please Refer Chapter‐2, Section‐2.3.3, Page
No. 2‐3 to 2‐44.
18 Action plan for the transportation of raw
material and products.
Transportation of all the raw materials and
products are primarily by road only and also
remain by same way after proposed
expansion.
19 Site‐specific micro‐meteorological data using Please Refer Chapter‐3, Section‐3.3.1 to
temperature, relative humidity, hourly wind
speed and direction and rainfall is necessary.
3.3.4, Table‐3.1 to 3.5, Page No. 3‐4 to 3‐8.
20 Ambient air quality monitoring at 6 locations
within the study area of 5 km., aerial
coverage from project site as per NAAQES
notified on 16th September, 2009. Location
of one AAQMS in downwind direction.
Please Refer Chapter‐3, Section‐3.4, Page
No. 3‐11 to 3‐18.
21 One season site‐specific micro‐
meteorological data using temperature,
relative humidity, hourly wind speed and
direction and rainfall and AAQ data (except
monsoon) for PM10, SO2, NOx including HC
and VOCs should be collected. The
monitoring stations should take into account
the pre‐dominant wind direction, population
zone and sensitive receptors including
reserved forests. Data for water and noise
monitoring should also be included.
For sit‐specific micro‐meteorological data:
Please Refer Chapter‐3, Table‐3.5, Page No.
3‐8.
For AAQ data: Please Refer Chapter‐3,
Section‐3.4, Page No. 3‐11 to 3‐18.
For water monitoring data: Please Refer
Chapter‐3, Section‐3.6, Page No. 3‐24 to 3‐
30.
For noise monitoring data: Please Refer
Chapter‐3, Section‐3.5, Page No. 3‐19 to 3‐
24.
22 Air pollution control measures proposed for
the effective control of gaseous emissions
within permissible limits.
Please Refer Chapter‐2, Section‐2.6.1.2,
Figure‐2.6, Page No. 2‐74 to 2‐77.
23 Name of all the solvents to be used in the
process and details of solvent recovery
system.
Please Refer Chapter‐2, Table‐2.3, Page No.
2‐52.
24 Design details of ETP, incinerator, if any
alongwith control of Dioxin & Furan, boiler,
scrubbers/bag filters etc.
ETP detail: please refer Chapter‐2, Section‐
2.5.3.1, Page No. 2‐58 to 2‐63.
At Site, the incinerable waste is sent to
CHWI for final disposal and after proposed
expansion, additional incinerable waste will
be disposed by same manner as existing.
Boiler Detail: Please Refer Chapter‐2,
Section‐2.6.1.1, Figure‐2.6, Page No. 2‐73 to
2‐74.
Scrubbers system: Please Refer Chapter‐2,
Section‐2.6.1.2, Figure‐2.6, Page No. 2‐74 to
2‐77.
25 Details of water and air pollution and its
mitigation plan.
For water pollution; Please refer Chapter‐2,
Section‐2.5.3, Page No. 2‐54 to 2‐63 &
Chapter‐6, Section‐6.4.3.1, Page No. 6‐8.
For air pollution; Please refer Chapter‐2,
Section‐2.6.1, Page No. 2‐72 to 2‐77 &
Chapter‐6, Section‐6.4.3.2, Page No. 6‐9.
26 Action plan to control ambient air quality as
per NAAQES Standards notified by the
Ministry on 16th September, 2009.
Adequate pollution control system will be
provided for control of emission. Ambient
air quality monitoring will be carried out
through out side competent approved
agency.
Please refer Chapter‐2, Section‐2.6.1, Page
No. 2‐72 to 2‐77 & Chapter‐6, Section‐
6.4.3.2, Page No. 6‐9.
27 An action plan to control and
monitor secondary fugitive emissions from all
the sources as per the latest permissible
limits issued by the Ministry vide G.S.R.
Please refer Chapter‐6, Section‐6.4.3.7, Page
No. 6‐13 to 6‐14.
414(E) dated 30th May, 2008.
28 Determination of atmospheric inversion level
at the project site and assessment of ground
level concentration of pollutants from the
stack emission based on site‐specific
meteorological features. Air quality
modelling for proposed plant.
Please Refer Chapter‐5, Section‐5.2.2, Page
No. 5‐12 to 5‐25.
29 Permission for the drawl of 53
m3/day ground water from the
CGWA/SGWB. Water balance chart including
quantity of effluent generated recycled and
reused and discharged.
We have applied for grant of permission for
abstraction of ground water to Central
Ground Water Authoriy, New Delhi. Please
Refer Annexure‐13. Page No. A‐40
Water balance chart including quantity of
effluent generated recycled and reused and
discharged: Please refer Chapter‐2, Figure‐
2.2, Page No. 2‐56 to 2‐57.
30 Narmada Canal water instead of ground
water should be the preferred source of
water for which efforts should be made with
concerned department and authority.
We will ensure to Sardar Sarovar Narmda
Nigam Ltd. (SSNNL), which is about 1.5 Km
away from project site, as optional water
supply if in case of non‐availability of ground
water. We have forwarded a request letter
to SSNNL regarding the same. Please refer
Annexure‐14. Page No. A‐47
31 Action plan for Zero Discharge of effluent as
proposed should be included.
After proposed expansion, total 24.95
m3/day waste water will be generated. To
treat the additional effluent load, company
is proposing a new ETP facility where
wastewater is treated by physico chemical
treatment. Treated effluent will be sent to
CETP of M/s. EICL, Umaraya for further
treatment & disposal or further passed
through Multiple Effect Evaporator followed
by Thin Film Dryer. After evaporation and
condensation, water is reused as boiler feed
water & in process. The unit maintains "Zero
Effluent Discharge." Company has valid
membership of CETP. Please refer
Annexure‐11. Page No. A‐38
32 Ground water monitoring minimum at 6
locations should be carried out. Geological
features and Geo‐hydrological status of the
study area and ecological status (Terrestrial
and Aquatic).
For water monitoring data: Please Refer
Chapter‐3, Section‐3.6, Page No. 3‐24 to 3‐
30.
Please Refer Chapter‐4, Section‐4.2, Page
No. 4‐4 to 4‐9.
33 The details of solid and hazardous wastes
generation, storage, utilization and disposal
particularly related to the hazardous waste
calorific value of hazardous waste and
detailed characteristic of the hazardous
waste. Action plan for the disposal of fly ash
generated from boiler should be included.
Please refer Chapter‐2, Section‐2.6.3, Table‐
2.9, Page No. 2‐78 to 2‐80.
Fly Ash generated from boiler will be sold to
nearest brick manufacturer.
34 Precautions to be taken during storage and
transportation of hazardous chemicals should
be clearly mentioned and incorporated.
Transportation of all the raw material and
products shall be primarily by road only. The
raw materials will be received in tanks,
HDPE/fiber drums, HMHDPE Carboys and
cylinders as well as through tankers. All the
storage tanks of hazardous flammable
substances will be located within premises
in separate storage area i.e. solvent farm
area. Solvent like Methanol, Toluene, IPA,
Xylene, etc. shall be stored in underground
MS/SS tank with all precautionary process
instrumentation and safety appliances.
Large area shall be covered by well‐designed
warehouse, which is containing store office,
raw material store, finished product store,
etc.
35 A copy of the Memorandum of
Understanding signed with cement
manufacturers indicating clearly that they
will utilized all the organic solid waste
generated.
Please refer Annexure‐15. Page No. A‐48
36 Details of land fill along with design details as
per CPCB guidelines. Location of secured land
fill/TSDF.
Secured land fill site operated by M/s
Nandesari Environment Control Ltd. (NECL),
is located in Nandesari about 23 km away
from the project site.
37 Authorization/Membership for the disposal
of liquid effluent in CETP and solid/hazardous
waste in TSDF.
Please refer Annexure‐11 and 12. Page No.
A‐38 and A‐39 respectively..
38 Ground water monitoring around the project
site as well as around land fill site.
For water monitoring data: Please Refer
Chapter‐3, Section‐3.6, Page No. 3‐24 to 3‐
30. Please refer Annexure‐18. Page No. A‐
57.
39 Risk assessment for storage for
chemicals/solvents and phosgenes. Action
plan for handling & safety system, whenever
any cyanide is involved in process.
Company is not using phosgene as raw
material or manufacturing the same in
existing scenario or not going to use or
manufacture in proposed scenario.
There is no any process which involved any
cyanide in existing as well as proposed
scenario.
For Risk assessment; please refer Chapter‐7.
40 An action plan to develop green belt in 33 %
area
Please refer Chapter‐6, Section‐6.4.3.5,
Table‐6.3, Page No. 6‐11 to 6‐13.
41 Action plan for rainwater harvesting Please refer Chapter‐6, Section‐6.4.3.8, Page
measures at plant site should be included to
harvest rainwater from the roof tops and
storm water drains to recharge the ground
water.
No. 6‐14 to 6‐16.
42 Occupational health of the workers needs
elaboration including evaluation of noise,
heat, illumination, dust, any other chemicals,
metals being suspected in environment and
going into body of workers either through
inhalation, ingestion or through skin
absorption and steps taken to avoid musculo‐
skeletal disorders (MSD), backache, pain in
minor and major joints, fatigue etc.
Occupational hazards specific pre‐placement
and periodical monitoring should be carried
out.
Please refer Chapter‐7, Section‐7.3.1 and
7.3.2, Page No. 7‐39 to 7‐40.
43 Socio‐economic development activities
should be in place.
Please Refer Chapter‐6, Section‐6.5, Page
No. 6‐19 and Annexure‐17, Page No. 54.
44 Note on compliance to the recommendations
mentioned in the CREP guidelines.
Please refer Annexure‐16, Page No. A‐49.
45 Detailed Environment management Plan
(EMP) with specific reference to details of air
pollution control system, water &
wastewater management, monitoring
frequency, responsibility and time bound
implementation plan for mitigation measure
should be provided.
Please Refer Chapter‐6.
46 EMP should include the concept of waste‐
minimization, recycle / reuse / recover
techniques, Energy conservation, and natural
resource conservation.
Please Refer Chapter‐6.
47 Any litigation pending against the project NA
and/or any direction/order passed by any
Court of Law against the project, if so, details
thereof.
48 Public hearing issues raised and
commitments made by the project
proponent on the same should be included
separately in EIA/EMP Report in the form of
tabular chart with financial budget for
complying with the commitments made.
‐
49 A tabular chart with index for point wise
compliance of above TORs.
‐
CHAPTER ‐ 1
INTRODUCTION
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CHAPTER – 1
INTRODUCTION
1.1 INTRODUCTION
M/s. Allchem Laboratories, existing advance pharmaceutical intermediates manufacturing
company, is located at Block No. 1088/B/P, 1088/A, Lamdapura Road, Village Manjusar, Taluka
Savli – 391 775, Dist: Vadodara, Gujarat. Allchem Laboratories is an ISO 9001:2008, 14001:2004
& OHSAS 18001:2007 certified company. A very small team of highly qualified scientists,
engineers and technicians is engaged in this process.
1.1.1 PROMOTERS& THEIR BACKGROUND
M/s. Allchem Laboratories is founded and promoted by Mr. Bipin K. Patel, M.Sc. (Organic
chemistry). He is well qualified and experience of pharmaceutical industry, pharmaceutical
chemistry, organic chemistry, etc. & specialized in executing research and development,
manufacturing of advance pharmaceutical intermediates, speciality chemical products. He has
good knowledge of lab/pilot plant production, commercial production, different type of
technologies used in this field and handling of different kind of chemicals at small quantity to
larger quantity. He is looking after all departments & see that project is successful in all the
way. The brief detail is as below;
1.1.1.1 EXPERIENCE
• He worked as R & D chemist in M/s. Rubamin Pharmaceuticals Pvt. Ltd, (ISO 9001 company)
and R & D executive in M/s. Parekh Laboratories Pvt. Ltd at Baroda.
• Total working experience in this filed around 17 years.
• Since, 2003, He has been continuing in M/s. Allchem Laboratories (Manufacturers of
speciality chemicals and advance pharmaceutical intermediates) at Baroda as Proprietor.
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1.1.1.2 TYPE OF WORK IN DIFFERENT AREAS
1.1.1.2.1 RESEARCH AND DEVELOPMENT
• Laboratory glassware selection and design as per process
• Laboratory autoclave (pressure reaction)
• Preparing samples for approval
• Isolation of product using distillation (high vacuum) or crystallization
• Procurement of laboratory chemicals for development purpose
• Library work like chemicals abstract, journals, patents, etc.
• To train the people and take out put from them
• Perfect housekeeping of laboratory
• Labeling of all the chemicals and keep in the systematic manner
• Making batch record in systematic manner
1.1.1.2.2 ANALYTICAL WORK (QC DEPARTMENT)
• Testing of all the raw materials, finished products and in process samples by all the possible
method as per GMP.
• Reagent preparation, standardization and calibration
• Familiar with titration like perchloric acid, acid‐base titration, chloride titration and many
more
• Familiar with GC (Shimadzu) with its parts (column) and maintenance etc.
• Familiar with HPLC, IR, Polariment, auto titrator etc.
• Evaluation of NMR spectra
• Making SOP for the instruments & calibration of the instruments.
• Making records of all the testing results
• Making certificate of analysis for dispatch
1.1.1.2.3 SCALE UP WORK (LAB > PILOT PLANT > COMMERCIAL PRODUCTION)
• Selection of pilot plant for multipurpose reactions (mainly utilized for custom synthesis
work and scale of the any products i.e. advance pharmaceutical intermediates)
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• Arrangement of glass assemblies, SS reactors, autoclave, vaccum ejector, scrubber and
centrifuges etc.
• Maintenance and operation of pilot plant
• Autoclave reaction using hydrogen pressure up to 15 kg/cm2 and temp up to 100 deg C
• Precious metal catalyst hydrogenation like Pd, Rh, Pt etc.
• During scale up lots of factors keep in mind like handling of hazardous chemicals in safe
manner, high production yield, avoid pollution, clean environment and maximum
production etc.
• High vaccum fractional distillation up to 0.05 mm in 5 lit to 400 lit reactors.
• Different purification techniques like distillation, crystallization etc.
1.1.1.2.4 KNOWLEDGE OF DIFFERENT TYPES OF TECHNOLOGIES
• Acetylation (‐C, ‐N, ‐O, ‐S etc.)
• Alkylation (‐C, ‐N, ‐O, ‐S etc.)
• Acylation (fridel craft reaction using aluminum chloride)
• Hydrolysis of nitriles, esters and amides
• Reductive amination
• Arylation of piperazines
• Bromination (ring as well as side chain) up to 170 deg C
• Chlorination (ring as well as side chain)
• Cyclization
• Decarboxylation
• Dimethyl sulphate reaction (at –N, ‐O, ‐S etc.)
• Hydrogenation using (raney Ni, Rh, Pd, Pt, etc.)
• Phase transfer reaction
• Ring closer reaction
• Acid chloride reaction and amide formation
• Esterification
• Mannich reaction
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• 1,4‐ addition
• Mannich reaction
• Griganard reaction
• High vaccum fractional distillation (0.05 mm of Hg)
• Dieckmann cyclization
• Stork enamine reaction
• Chloromethylation reaction
• Vilsmeier haak reaction
• Gabriel synthesis
• Hoffman degradation
• Knoevenagel condensation
• Reduction using sodium borohydride, aluminium hydride, aluminium isopropoxide, Iron
powder, Raney nickel with hydrazine hydrate, etc.
1.1.1.2.5 HANDLING OF DIFFERENT KINDS OF CHEMICALS
• Thionyl chloride up to 1000 kg level
• Aluminum chloride anhydrous during fridel craft acylation
• Sodium cyanide up to 400 kg level at a time
• Phosphorous oxychloride up to 300 kg level
• Sodium azide reaction up to 10 kg level
• Grignard reagents
• Oxalyl chloride handling and reactions
• Bromine and chlorine in halogenations step
• Sodium metal and potassium metal
• Sodium amide and potassium amide formation
• Sodium methoxide and sodium ethoxide generation
• All flammable solvents like toluene, ether, Xylene, methanol, MDC, ethyl acetate, acetone,
IPA, hexane, DMF etc.
• Dry HCl gas generation at plant level
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• All types of acids and strong bases
• Acid chlorides and anhydrides
• Raney Nickel in autoclave
• Sodium borohydride for reduction at low as well as high temp.
• Precious metal catalyst (Pd, Pt, Rh, Ru etc.)
• Handling of low temperature reactions using dry Ice (up to ‐70 deg C)
1.1.1.2.6 DIFFERENT TYPES OF DERIVATIVES
• Drug intermediates like, domperidone, cetrizine, astemazole, nimesulide, buflomedil,
quatipine, ebastine, carvedilol, meloxicam, sibutramine, cefuroxime, cefazolin, ceftrixone
Iritocan, Trazodone and many more
• Piperazine derivatives (aryl and aliphatic)
• Piperidone and piperidine derivatives
• Cycloalkane derivaties
• Aldehyde and ketone derivatives
• Carboxylic acid and derivatives
• Amine derivatives (aryl, aliphatic and bezylic )
• Hetrocyclic derivaties (pyrimidine, imidazole, benzimidazole, benzothiozole, etc.)
• Custom synthesis and contract research type of products ranging from 20 gm to 50 kg level
1.1.1.2.7 UTILITIES EQUIPMENTS
• Handling of various utility equipments during process scale up for commercial production
like, boiler, thermic fluid, water ejector, chilling plant, cooling tower, centrifuges, air
compressor, etc.
• Handling of various equipment during commercial production Dryers, high vaccum pumps,
scrubbers, glass line reactors, SS reactors and handling of various hazardous chemicals in
safe manner.
• Transferring solid and liquid from reactor to reactor
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1.1.1.2.8 ELECTRICAL KNOWLEDGE
• Calculation of electrical load in the company
• GEB licensing work like application
• Single phase wiring knowledge, three phase wiring
• Knowledge of electric motors, electrical heaters, MCB, Starter, Electrical penal, Checking of
earthings, Voltage checking, distribution of electrical load, etc.
1.1.1.2.9 CHEMICALS SOURCING KNOWLEDGE
• He has visited seven times CPhI which is held in Europe at Germany, Belgium, Spain and
France. From these fairs He came to know there is lot of potential for the supply of advance
pharmaceutical intermediates.
• Knowledge of lots of sourcing database
• These are the very important things for custom synthesis work and making of advance
pharmaceutical intermediates.
1.1.1.2.10 MARKETING WORK RELATED TO PHARMACEUTICALS (FINE CHEMICALS, DRUG
INTERMEDIATES AND ORGANIC CHEMICALS)
• He has visited seven times CPhI which is held in Europe at Germany, Belgium, Spain and
France.
• From these fairs He came to know lots of new customers (Fine chemicals, drug
intermediates and organic chemicals) related to pharma industries, their requirements, etc.
• Selection of the products, decide the pricing and make viable on commercial levels.
• Conveyance to customer and take the orders from them.
1.1.2 JUSTIFICATION OF PROJECT M/s. Allchem Laboratories is located in Savli Taluka has population of around 2,05,478 and
Savli village which is about 15 km away and has all essential facilities such as water, power, fuel,
post, telecommunication, bank, etc. and is well connected by road and rail to rest of India.
Development of Communication systems is good in the region. Sources of water in the region
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include river and ground water resources. Nearer village is lamdapura which is about 1.5 Km
away from the project site. Vadodara city, the commercial city of Gujarat, is about 29 km and
airport is about 13 km away from project site. The project site is located about 8 km away from
National Highway No. 8 & 0.5 km, 11.05 km, 11.11 km, 11.8 km away from State Highway No
158, 87, 63 and 150 respectively. The nearest Broad‐gauge railway station is vadodara at 29 Km.
However, the predominant mode of transportation in the area is by network of roads only.
Main source of water in the area surrounding to plant site is ground water. The river Mahi flows
10 km distance from the project site.
Project site, where M/s. Allchem Laboratories, is located, comes under Vadodara District, which
is 29 km away from Nandesari GIDC an important industrial city of Gujarat and India. In
addition, it is a major centre of the pharmaceutical and glass industry in India; the basic
chemical industry is also a growing one. At Koyali nearby is a large oil‐refinery and at Ranoli
petro‐chemical‐based industries; while at Bajwa there is a fertilizer factory.
Towns like Padra, Anand, Bharuch, etc. are quite near to this project site. This makes Vadodara
an ideal location for transportation, communication, residential and manpower availability.
Common effluent treatment plant operated by M/s. Enviro Infrastructure Control Ltd., Umaraya
is located about 35 Km away from the project site. Secured land fill site and Common
Incineration facility operated by M/s Nandesari Environment Control Ltd. is located in
Nandesari about 23 km away from the project site.
1.2 PROJECT DETAILS
M/s. Allchem Laboratories is an existing unit of very small capacity. M/s. Allchem Laboratories is
an ISO 9001:2008, 14001:2004 & OHSAS 18001:2007 certified company. In order to meet
commercial quantities demand, the growing market demand and availability of space for
manufacturing facility at existing premises, M/s. Allchem Laboratories proposes to expand
manufacturing activities by introduction of new products at existing unit. As proposed project
activity comes under category A‐5(f) (Industrial Project) as per EIA notification, 2006 of Ministry
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of Environment & Forest under the provisions of Environmental Protection Act, 1986. Since this
proposed project activity require Environmental Impact Assessment Studies and Environmental
Clearance, the Company has entrusted M/s. Aqua‐Air Environmental Engineers Pvt. Ltd., Surat
for carrying out the EIA Studies as per the prevailing rules and regulations. Company has
applied for Environmental Clearance to Ministry of Environment & Forests. TOR Presentation to
Expert Appraisal Committee of MoEF was done on December 23, 2010. TOR has been finalized
in the meeting, including certain additional points. M/s. Aqua‐Air Environmeantal Engineers
Pvt. Ltd., Surat has carried out EIA Studies as per TOR and guidelines of EAC, MoEF, New Delhi.
As the project under consideration is expansion activity, the suitability of the project site has
been assessed in the report. A mitigation plan has been prepared and a detailed environmental
management plan (EMP) is drawn out to effectively mitigate or minimize potentially adverse
environmental impacts and the details are presented in the following chapters. The list of
existing & proposed products along with their productions capacity is given in Table 1.1 as
below;
TABLE 1.1
LIST OF PRODUCTS ALONG WITH THEIR PRODUCTION CAPACITY (EXISTING & PROPOSED)
Quantity
(MT/Month)
Sr.
No.
PRODUCTS
Existing Total After Proposed
Expansion
1 1‐Benzylpiperazine, 99% 0.100 0.100
2 Dibutyl oxalate, 98% 0.100 0.100
3 1,4‐Piperazinedicarboxaldehyde, 99% 0.100 0.100
4 1,4‐Dibromobutane, 99% 0.100 0.100
5 1‐(4‐Fluorophenyl)piperazine, 99% ‐ 0.500
6 1‐Benzyldiethanolamine, 98% 0.050 0.050
7 1‐(3‐Chlorophenyl)piperazine, 99 % ‐ 8.000
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Other Aryl piperazines
1‐[2‐(2‐Hydroxyethyl)ethoxy]piperazine, 99 % 8
Other aliphatic piperazines
‐ 3.000
1‐(3‐Chloropropyl)‐4‐(3‐chlorophenyl)piperazine
hydrochloride, 98 %
9
Other amines hydrochlorides
‐ 12.000
1‐(2‐Methoxyphenyl)piperazine hydrochloride,
98 %
10
Other Aryl Piperazine hydrochlorides
‐ 2.000
Isovaleryl chloride, 98 % 11
Other Acid chlorides
‐ 1.500
2‐Methoxybenzylamine, 98 % 12
Other benzylamines
‐ 0.500
1‐Benzyl‐4‐piperidone, 98 % 13
Other piperidones
‐ 2.000
Veratraldehyde, 98 % 14
Other aldehydes
‐ 0.500
1‐Indanone, 98 % 15
Other ketones
‐ 2.000
1‐(4‐Fluorophenyl)piperazine, 98 % 16
Other Aryl Piperazines
‐ 0.500
N‐Acetyl‐4‐piperidinecarboxylic acid, 99 % 17
Other piperidines
‐ 1.000
4'‐Chlorobenzhydrol, 98 % 18
Other benzhydrol
‐ 0.500
Heptylamine, 99 % 19
Other aliphatic amines
‐ 5.000
20 4‐Benzyloxyaniline HCl, 98 % ‐ 0.500
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Other anilinehydrochlorides
Cyclobutanecarboxylic acid, 98 % 21
Other carboxylic acids
‐ 0.500
22 Diethyl cylopentanceaboxylate, 98 % ‐ 0.500
Other carboxylic esters
1‐Iodonathalene, 98 % 23
Other aromatic halides
‐ 0.500
1‐Allyl imidazole, 98 % 24
Other imidazoles
‐ 0.250
2‐Chlorobenzimidazole, 98 % 25
Other benzimidazoles
‐ 1.500
1‐(4‐Chlorophenyl)cyclobutanecarbonitrile, 98 % 26
Other carbonitriles
‐ 1.000
3,5‐Dimethyl‐4‐cyanophenol, 98 % 27
Other benzonitriles
‐ 0.500
1‐Boc‐3‐piperidone, 97 % 28
Other Boc amides
‐ 0.500
1‐(3‐Chloropropyl)‐2‐benzimidazolidinone, 98 % 29
Other benzimidazoles
‐ 3.000
1‐Pyrrolidinebutanenitrile, 98 % 30
Other pyrrolidines
‐ 1.000
1‐(4‐Chlorophenyl)‐4‐hydroxypiperidine, 98 % 31
Other piperidines
‐ 0.750
32 R & D Project (Less than 25 Kg each) ‐ 1.000
33 Kilo Lab (25 Kg to 500 Kg) ‐ 1.500
34 Advance Pharma Intermediates ‐ 3.500
Total 0.45 55.95
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TABLE‐1.1 (CONTD.)
BY‐PRODUCTS ALONG WITH THEIR PRODUCTION CAPACITY
Quantity
(MT/Month)
Sr.
No.
PRODUCTS
Existing Total After Proposed
Expansion
1 Sodium Chloride 0.048 16.048
2 Potassium chloride 0.031 2.511
3 Sodium bromide ‐ 7.86
4 Potassium bromide ‐ 1.39
5 Ammonia solution 25% in water ‐ 1.94
6 Hydrochloric acid 30% in water ‐ 4.125
7 Hydrobromic acid 48% in water ‐ 8.22
8 Sodium Sulphite ‐ 2.115
9 Polyaluminium Chloride ‐ 2.286
10 Cuprous bromide ‐ 0.65
Total 0.079 47.145
1.2.1 REGULATORY FRAMEWORK
For proposed project, following assumption has been considered;
• Capacity of Plant 55.95 MT/ Month
• Total working days in a year around 315 days
• Raw material storage facility for 30‐45 days
• Finished product storage in drums for 8 tons
• Solvent storage for 30 days
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1.3 PROJECT SETTING
1.3.1 LOCATION
M/s. Allchem Laboratories is located at 22° 26' 45.178656" North latitude and 73° 11'
5.395236" East longitude. Location & study area of the Project Site is shown in Figure‐1.1.
Detailed layout map of the plant is shown in Figure – 1.2. A map indicating location of the
project and distance from severely polluted area is shown in Figure‐1.3. Total area covered by
Vadodara is about 693.43 Sq. Km. Total area covered by Savli taluka is about 792 Sq. Km.
Important places around Plant are:
Savli city ‐To the North
Vadodara City ‐ To the South‐East
The salient features of the site are as under;
1. Minimum distances:
a) From City : Vadodara 29 km (Population 13,41,575)
b) Village : Manjusar 2.5 km (Population – 3,716)
c) Historical Site : None
d) Sanctuaries : None
e) Highway : National Highway No. 8 (8 km South‐West), State Highway SH 158 (0.55 km East)
State Highway SH 87 (11.05 km South‐East)
State Highway SH 63 (11.11 km North‐East)
State Highway SH 150 (11.8 km North‐East)
F) Sea coast : 55 km
g) CETP location : 35 km
h) Secured landfill site : 23 km
2. Use of forest land : None
3. Use of prime agricultural land: None
4. Planned submergence : None
5. Displacement of population : None
________________________________________________________________________________________________________________ D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 1‐13
FIGURE ‐ 1.1
STUDY AREA
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FIGURE ‐ 1.2
LAYOUT OF THE PLANT
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FIGURE ‐ 1.3
MAP TO DISTANCES OF CRITICALLY/SEVERELY POLLUTED AREA FROM THE PROJECT SITE (GOOGLE MAP)
74.58 Km
105 Km
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1.3.2 KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS
1.3.2.1 METHOD OF DATA PREPARATION
Key infrastructure features have been extracted from Survey of India (SoI) topographical maps
of 1:50,000 scale. The features have been updated using satellite data and have been verified
with ancillary information derived from TTK maps and guide maps. The locations of the
settlement have been extracted from Census of India (CoI) maps and have been verified by
using SoI topographical maps and satellite data.
1.3.2.2 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE
The distance of railways and National & State highways are presented in Table 1.2 as below.
There is no National Park/Wild life sanctuary/ Reserve Forest falls within 10 Km radial distance
from the project site.
TABLE 1.2
DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE
SR.
NO.
NEAREST INFRASTRUCTURE FEATURE DISTANCE FROM PROJECT SITE
1 Village Manjusar 2.5 Km in South‐East Direction
2 NH‐8 8.0 Km in South‐West Direction
3 NE1 (Ahmedabad Vadodara Expressway) 8.0 Km in South‐West Direction
4 SH‐158 0.50 Km in East Direction
5 SH‐87 11.05Km in South‐East Direction
6 SH‐63 11.11 Km in North‐East Direction
7 SH‐150 11.80 Km in North‐East Direction
8 Railway line 4.52 Km in South‐East Direction
9 Mahi River 10.27 Km in West Direction
10 Vadodara Airport 22 Km in South‐East Direction
(Courtesy: Environmental Information Center, New Delhi)
________________________________________________________________________________________________________________ D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 1‐17
1.3.2.3 MAP OF KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS
A map depicting administrative boundaries up to Taluka level, showing locations of towns and
villages along with National and State highways, major and medium roads and railways is
presented as Figure 1.4. The map also shows the water bodies and forest boundaries for better
understanding of project area. The map marks the area within 10 km with the project site as
the center. Satellite imagery of area around 10 km radial distance from the project site as
center is shown in Figure‐1.5.
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FIGURE‐1.4
KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS
1. Basemetal Chemicals 2. Anugrah In‐org pvt. Ltd. 3. Universal Esters Pvt. Ltd 4. Gurunanak Industries 5. J.R.Corporation 6. Uma Organics
________________________________________________________________________________________________________________ D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 1‐19
FIGURE‐1.5
SATELLITE IMAGERY ALONG WITH PRESENT LAND USE PATTERN
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1.4 PURPOSE OF EIA
The purpose of EIA study is to critically analyzed the construction and operation phase activity
of proposed project with respect to manufacturing process of different products with reference
to types and quantity of raw material consumption, possible source of water consumption &
wastewater, air emission and hazardous waste generation, control measures to reduce the
pollution and to delineate a comprehensive environment management plan along with
recommendations and suggestions based on the finalized TORs by EAC, New Delhi.
1.5 OBJECTIVES OF EIA
The main objectives of the study are
1) To assess the background environmental status.
2) To identify potential sources of pollution.
3) To predict and evaluate the impact on environment along with pollution control
measures taken.
4) To prepare a comprehensive Environment and Disaster Management Plan.
1.6 METHODOLOGIES FOR EIA
Taking into consideration proposed project activities and guidelines, an area of 10 km radius
from the center of the project has been selected and is designated as the study area for the
purpose of EIA study.
1.6.1 Base Line Environmental Condition
The samples of ambient air, ground & surface water and soil are collected and analyzed as per
the standard methods for establishing the baseline data and to determine the impact of
proposed activity on the same.
1.6.1.1 Ambient Air Environment
The air environment around the plant was studied by setting up eight locations within the study
area of 10 Km radius from the project site and collection & monitoring the site specific
________________________________________________________________________________________________________________ D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 1‐21
meteorological data, viz. wind speed and direction, humidity, rainfall and ambient temperature.
Design of network for ambient air quality monitoring location is based on guidelines provided
by CPCB. The ambient air samples were collected and analysed for SPM, PM2.5, PM10, SO2, NOx,
O3, Pb, CO, NH3, C6H6, Benzo (a) Pyrene (BaP) particulate phase only, As, as Ni, HC and VOCs for
identification, prediction, evaluation and assessment of potential impact on ambient air
environment.
1.6.1.2 Ground And Surface Water Environment
The water required for domestic and industrial uses is being made available from ground water
only. Hence, to assess the physico‐chemical quality of the water, a number of water samples
were collected and analyzed for pollution parameters viz., pH, TDS, TSS, BOD3, COD, Fluorides,
Chlorides, Sulphates, Nitrates, Ammonical Nitrogen, Alkalinity, Iron, etc. and some trace heavy
metals in order to find out the contamination, if any.
1.6.1.3 Noise Environment
Noise pollution survey was conducted in the study zone for evaluating existing status. The
anticipated noise sources were automobile activities, which are likely to be increased due to
proposed activity. Noise levels were also recorded at the noise generating places and in the
surrounding villages for evaluating general scenario of the study area. Hourly equivalent sound
levels (Leq) were also recorded for calculating Day and Night noise levels in the surrounding
villages.
1.6.1.4 Soil Environment
Soil sampling and analysis was carried out to assess physico‐chemical characteristics of the soils
and delineate existing cropping pattern, existing land use and topography, within the study
area. Identification of potential utilities of effluent in land application and subsequent impacts
are assessed.
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1.6.1.5 Biological Environment
Keeping in view, the importance of biological component of total environment due to the
proposed project activity, biological characterization of terrestrial and aquatic environments,
changes in species diversity of flora and fauna in terrestrial as well as aquatic systems were
studied for impact analysis due to proposed project activity.
1.6.1.6 Socio‐economic Environment
Demographic and related socio‐economic data was collected from census handbook and EIC to
assess socio‐economic status of study area. Assessment of impact on significant historical,
cultural, and archeological sites/places in the area and economic and employment benefit
arisen out from the project activity is given special attention.
1.6.2 Identification of Source of Pollution
Detailed studies of manufacturing process are carried out along with input and output of
materials, water, and wastewater as well as infrastructure facilities available.
1.6.3 Evaluation of Pollution Control and Environmental Management System
The qualitative and quantitative analysis of various pollution sources as well as evaluation of
pollution control system is carried out.
Evaluation of Impact
A comprehensive evaluation of environmental impact with reference to proposed expansion
activities is carried out.
1.6.4 Preparation of Environmental Management Plan
A comprehensive Environmental Management Plan has been prepared covering all the aspects
of pollution prevention measures, Air and Water Pollution Control measures, Hazardous Waste
Management, Environmental Surveillance and Environmental Management Plan.
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The present report is a rapid EIA conducted during winter season of January to March, 2011.
The baseline environmental conditions have been established through field monitoring and
literature survey. The contents of EIA report, details of data collection and source of secondary
data are presented in Figure 1.6.
1.7 STRUCTURE OF REPORT
The objectives of the EIRA study is preparation of Environment Impact and Risk Assessment
(EIRA) report based on the guidelines of the Ministry of Environment and Forests (MoEF), CPCB
and GPCB, Incorporating;
Chapter‐1: Introduction
This chapter provides an Introduction of Industry, their premises and surrounding areas. It is
also expressing the basic objectives and methodologies for EIA studies and work to be covered
under each Environment component.
Chapter‐2: Project Description and Infrastructural Facilities
This chapter includes Project Description and Infrastructure facilities delineating all industrial
and environmental aspect of M/s. Allchem Laboratories. Construction and operation phase
activities as well as manufacturing process of existing as well as proposed products. This
chapter gives information about raw material storage and handling, water and wastewater
quantitative details, air pollution and control system, sludge storage facility, utilities, greenbelt
and safety measures for proposed project activity.
Chapter‐3: Baseline Environmental Status
This chapter provides Base Line Environmental Status delineating meteorological details and
identification of base line status of Environmental components (primary data) of surrounding
area.
________________________________________________________________________________________________________________ D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 1‐24
Chapter‐4: Land Use Pattern, Biological Environment and Socio Economic Environment
This chapter presents a study of land use pattern, Biological Environment & Socio‐Economic
Environment giving details about District Vadodara, Taluka Savli and the study area in terms of
land use pattern, biological environment, and socio‐economic environment.
Chapter‐5: Identification, Prediction and Evaluation of Impact with Environment
Management System
This chapter includes Identification and Prediction of Impact, which provides quantification of
significant impacts of the proposed project activities of plant of various environmental
components. Evaluation of the proposed pollution control facilities is also carried out in this
chapter.
Chapter‐6: Environmental Management Plan
This chapter includes Environment Management plan delineating preparation of Environment
Management Plan (EMP) to be adopted for mitigation of anticipated adverse impacts if any,
and to ensure acceptable impacts.
Chapter‐7: Risk Analysis & Disaster Management Plan
This chapter provides details of Risk Analysis and Disaster Management Plan; it provides basis
for what should be type and capacity of its on‐site and off‐site emergency plan also what types
of safety measures are required. Risk and consequence analysis is carried out considering
storage and handling of various hazardous raw materials, intermediates and product as well as
manufacturing process.
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 1‐ 25
FIGURE – 1.6
E.I.A. PLAN & PROCEDURE
RECONNAISSANCE SURVEY OF EXISTING PLANT
ANNUAL REPORT MARKET ASSESSMENT FINANCIAL REPORT PROJECT REPORT
INTRODUCTION
MONITORING OF AIR, WATER & SOIL QUALITY & NOISE LEVELS. DATA ON METEOROLOGY SOCIO‐ECONOMIC STATUS & BASIC AMENITIES. SITE VISITS BY AND INTERVIEWS WITH LOCALS
BASELINEENVIRONMENTAL
STATUS
ENVIRONMENTAL INFORMATION CENTRE CENTRAL GROUND WATER BOARD GUJARAT POLLUTION CONTROL BOARD (GPCB) PUBLIC HEALTH ENGINEERING DEPT. AGRICULTURE DEPARTMENT FOREST DEPARTMENT IRRIGATION DEPARTMENT EMPLOYMENT EXCHANGE HEALTH CENTER CENSUS DEPT. INDIAN METEOROLOGICAL DEPT.
SOCIOECONOMICSTATUS &
INFRASTRUCTURE
EXISTING PLANT
FACILITY DESCRIPTION
IMPACTS METHODOLOGY OF
IMPACT ASSESSMENT
IDENTIFICATION & ASSESSMENT OF IMPACTS EVALUATION OF IMPACTS BY MATRIX METHOD
SOURCE OF INFORMATION OVERVIEW OF
E I A STUDIES
ACTIVITIES
ENVIRONMENTAL MANAGEMENT PLAN
DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR POLLUTION CONTROL, HAZARDOUS WASTE MANAGEMENT, GREEN BELT DEVELOPMENT MONITORING PROGRAM
RISK ANALYSISSTUDIES & DISASTER
MANAGEMENT PLAN
SAFETY, HEALTH & ENVIRONMENTAL POLICY, GUIDELINES BY DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR. CONSEQUENCE ANALYSIS
PREPARATION OF DISASTER MANAGEMENT PLAN
CHAPTER ‐ 2
PROJECT DESCRIPTION
AND
INFRASTRUCTURAL FACILITIES
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2‐ 1
CHAPTER ‐ 2
PROJECT DESCRIPTION AND INFRASTRUCTURAL FACILITIES
2.1 BACKGROUND
M/s. Allchem Laboratories is advance pharmaceutical intermediates manufacturing company
and plans to introduce new products at company premises by using existing as well as
additional manufacturing and infrastructure facilities. Various utilities i.e. boiler, thermic fluid
heater, cooling tower, brine plant, chilling Plant, RO water plant, air compressor, DM water
plant, DG set, etc. are the utilities will be proposed to install to meet the requirements.
2.2 PROJECT COST
Total capital investment for the proposed project activities is Rs. 276 Lacs. It includes land,
site development, construction, plant machineries, environment protection measures cost,
etc. Break up of proposed investment is shown in Table‐2.1.
TABLE‐2.1
BREAK UP OF PROPOSED INVESTMENT
SR. NO. PARTICULARS AMOUNT
( Rs. IN LACS) 1 Land 16.0
2 Office Building 1.0
3 Research & Development 5.0
4 Quality control lab 19.0
5 Production plant Equipment 123.0
6 Utilities building 20.0
7 Effuent Treatment plant 42.0
8 Green Belt 3.0
9 Storage Godown 15.0
10 Road, Parking & open sky 5.0
11 Solvent storage 5.0
12 Fuel storage 3.0
13 Toilets, Security, canteen, clock room, Rest room 5.0
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2‐ 2
14 Storage water 3.0
15 Storage (Hazadous Waste) 2.0
16 Storage (Hazardous chemicals) 3.0
17 Storage (Others) 3.0
18 Borewell 1.0
19 Sockpit 2.0
Total 276.0
TABLE‐2.1 (CONTD.)
MEANS OF FINANCE
SR. NO. PARTICULARS (Rs. IN LACS)
1 Member Contribution & Internal Accrual 76.0
2 Loan 200.0
TOTAL 276.0
2.3 MAIN PHASES OF THE PROJECT
2.3.1 PRE CONSTRUCTION ACTIVITIES
At project site, there is sufficient road communication is available so there is no need to
construct any approach road or site access. There is a clear provision for space and proposed
project activity is located on level ground which does not require any land filling for area
grading work. The site is to be cleaned and leveled in a way so that there is no additional soil
to be brought from out side. No major pre‐construction activities are anticipated.
2.3.2 CONSTRUCTION ACTIVITIES
All Construction and commissioning activities of proposed expansion project shall be carried
out after getting Environmental Clearance from MoEF, New Delhi. Erection of various
machineries shall start simultaneously.
• Construction of building, Plant & infrastructure facilities.
• Construciton of sheds and other essential utilities shall be carried out.
Construction materials required for the project activity like steel, cement, crushed stones,
sand, rubble, etc. shall be procured from the local market of the region.
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2‐ 3
2.3.3 MANUFACTURING ACTIVITIES
Manufacturing activities proposed in the project include various processes as a part of
manufacturing existing as well as proposed products. The activities shall also include
operation of various utilities. The manufacturing process is described in details in following
sections. The list of products (existing as well as proposed) and their capacity is given in Table
1.1.
2.3.3.1 1‐BENZYLPIPERAZINE, 99%
2.3.3.1.1 Process Description
Benzylchloride is reacted with piperazine in the presence of an organic solvent such as
toluene at 70 °C for 8 hours to give 1‐Benzylpiperazine hydrochloride. Hydrochloride salt of
the 1‐Benzylpiperazine neutralise with sodium hydroxide to give 1‐Benzylpiperazine, sodium
chloride and water. The by product sodium chloride is filltered off in pure form (while water
generated during neutralization will be retained by the wet cake of sodium chloride which will
be lost during drying). After filtration organic layer taken for distillation to remove the solvent.
The final product (1‐Benzylpiperazine) is dried under vaccum to remove traces of moisture.
2.3.3.1.2 Chemical Reaction
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2.3.3.1.3 Material Balance
Input Qty in kg Output Qty in kg
Benzyl chloride 7.182 1‐Benzylpiperazine 10.000
Piperazine 4.886 Sodium chloride 3.314
Solvent (toluene) 10.000 Water 1.022
Sodium hydroxide 2.268 Solvent (toluene) 10.000
Total 24.336
Total 24.336
Note: Water generated during the process will be retained by the wet cake of the sodium
chloride which will be lost during the drying.
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2.3.3.2 DIBUTYL OXALATE, 98%
2.3.3.2.1 Process Description
Oxalic acid is reacted with n‐Butanol in the presence of organic solvent such as toluene at 100
°C for 4 hours and then remove water by azeotropic distillation. (theoretical quan tites). After
removal of water start distillation of solvent. The final product (Dibutyl oxalate) is dried under
vaccum to remove traces of moisture.
2.3.3.2.2 Chemical Reaction
2.3.3.2.3 Material Balance
Input Qty in kg Output Qty in kg
Oxalic acid 4.452 Dibutyl oxalate 10.000
n‐Butanol 7.328 Water 1.780
Solvent (toluene) 10.000 Solvent (Toluene) 10.000
Total 21.780
Total 21.780
Note : Water generated during the process is as good as distilled water, because in the
process water is removed by azeotropic distillation.
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2.3.3.3 1,4‐PIPERAZINEDICARBOXALDEHYDE, 99%
2.3.3.3.1 Process Description
Formic acid (85%) is reacted with piperazine in the presence of an organic solvent such as
Xylene at 110 °C for 11 hours (slow addition of formic acid, 85%). After then remove water by
azeotropic distillation to give 1,4‐Piperazinedicarboxaldehyde. Cool the reaction mixture
under strring to room temperature, filter the solid and reuse the solvent directly for the next
step.
2.3.3.3.2 Chemical Reaction
2.3.3.3.3 Material Balance
Input Qty in kg Output Qty in kg
Formic acid (85%) 7.617 1,4‐Piperazinedicarboxaldehyde 10.000
Piperazine 6.058 Water (from acid & rxn.) 1.780
Solvent (Xylene) 10.000 Solvent (Xylene) 10.000
Total 23.675
Total 23.675
Note: Water generated during the process is as good as distilled water, because in the
process water is removed by azeotropic distillation.
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 7
2.3.3.4 1,4‐DIBROMOBUTANE, 99%
2.3.3.4.1 Process Description
1,4‐Butanediol is reacted with hydrobromic acid (48%) in the presence of an organic solvent
such as toluene at reflux temp and slowly remove water by azeotropically distillation
contineously till end of reaction. After completion of the raction distilled out solvent. The final
product 1,4‐Dibromobutane is dried under vaccum to remove traces of moisture.
2.3.3.4.2 Chemical Reaction
2.3.3.4.3 Material Balance
Input Qty in kg Output Qty in kg
1,4‐Butanediol 8.347 1,4‐Dibromobutane 20.000
Hydrobromic acid (48%) 31.223 Water (from acid & rxn.) 19.570
Solvent (Toluene) 20.000 Solvent (Toluene) 20.000
Total 59.570
Total 59.570
Note: Water generated during the process is as good as distilled water, because in the process
water is removed by azeotropic distillation.
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 8
4-Fluoroaniline Bis(2-chloroethy Pottasium 1-(4-Fluorophenyl) piperazine Pottasium Water
amine)HCl carbonate Chloride
F NH2 NH.HCl
Cl
Cl
K2CO3Isopropyl aclohol
80 deg C for 12 hrs.N NHF KCl H2O
2.3.3.5 1‐(4‐FLUOROPHENYL) PIPERAZINE, 99%
2.3.3.5.1 Process Description
4‐Fluoroaniline is reacted with Bis(2‐chloroethylamine)HCl in the presence of an organic solvent
such as IPA & pottasium carbonate at 80 °C for 12 hours to give 1‐(4‐Fluorphenyl)pierazine and
pottasium chloride. Reaction continues till no more carbon dioxide is evolved. The by product
pottasium chloride is filltered off in pure form (while water generated during
reaction/neutralization will be retained by the wet cake of pottasium chloride which will be lost
during drying). Filltrate taken for distillation to remove the solvent. The final1‐(4‐
Fluorphenyl)piperazine, 99% is dried under vaccum to remove traces of moisture/solvent.
2.3.3.5.2 Chemical Reaction
2.3.3.5.3 Material Balance
Input Qty in kg Output Qty in kg
4‐Fluoroaniline 3.082 1‐(4‐Fluorophenyl) piperazine 5.000
Bis(2‐Chloroethylamine) HCl 4.951 Potassium chloride 6.203
Potassium carbonate 5.750 Water 0.750
Isopropyl alcohol 20.000 Carbon dioxide 1.830
Isopropyl alcohol 20.000
Total 33.783
Total 33.783
Note: Water generated during the process will be retained by the wet cake of the
potassium chloride which will be lost during the drying.
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2.3.3.6. 1‐BENZYLDIETHANOLAMINE, 98%
2.3.3.6.1 Process Description
Benzyl chloride is reacted with Diethanolamine in the presence of an organic solvent
(Methylene dichloride) and sodium carbonate at 30 °C for 20‐22 hrs. to give 1‐
Benzyldiethanolamine and sodium chloride and water. The by product sodium chloride is
filtered off in pure form (while water generated during neutralization will be retained by the
wet cake of sodium chloride which will be lost during drying). After filtration organic layer taken
for distillation to remove the solvent. The final product (1‐Benzyldiethanolamine) is dried under
vaccum to remove traces of moisture.
2.3.3.6.2 Chemical Reaction
2.3.3.6.3 Material Balance
Input Qty in kg Output Qty in kg
Benzyl chloride 16.230 1‐Benzyldiethanolamine 25.030
Diethanolamine 13.480 Sodium chloride 7.500
Sodium carbonate 6.795 Water 1.154
Methylene dichloride 40.000 Carbon dioxide 2.821
Methylene dichloride 40.000
Total 76.505
Total 76.505
Note: Water generated during the process will be retained by the wet cake of the sodium
chloride which will be lost during the drying.
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Cl
NH2 NH.HCl
Cl
Cl
1-(3-Chloropheny)piperazine
3-Chloroaniline
Bis(2-Chloroethylamine)hydrochloride
Sodium hydroxide, water
N NH
Cl1-(3-Chlorophenyl)piperazine
NaCl
Sodium chloride
M.W. 127.57
M.W. 178.49
M.W. 40
M.W. 196.68M.W. 58.44
Toluene
2.3.3.7 1‐(3‐CHLOROPHENYL)PIPERAZINE, 99 % 2.3.3.7.1 Process Description Into reactor, charge 745 Kg water, 305 Kg 3‐chloroaniline, 427 Kg Bis (2‐Chloroethyl) amine hydrochloride and 287 Kg sodium hydroxide at room temperature. Take temperature 90 °C within 15 hours. Monitor the reaction performance by analytical method. After completion of reaction cool to 35 °C and add 916 lit Toluene at 35 °C in 2 hrs. Stirr for 1 hrs and filter the sodium chloride (inorganic salts) slurry and collect the filtrate separately. Separate organic layer and take for the solvent recovery. After solvent recovery finally apply full vacuum to distill final product 1‐(3‐Chlorophenyl) piperazine. Expected weight is 400 Kg.
2.3.3.7.2 Chemical Reaction
2.3.3.7.3 Material Balance Total number of batches: 20 numbers
Input Qty in kg Output Qty in
kg
3‐Chloroaniline 305 1‐(3‐Chlorophenyl)piperazine 400
Bis‐(2‐Chloroethyl)amine hydrochloride
427 Sodium chloride 420
Sodium hydroxide 287 Water 745
Toluene 916 Water generated from reaction 129
Water 745 Recovered Toluene 885
Toluene Loss 31
Distillation Residue 71
Total 2680
Total 2680
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2.3.3.8 1‐[2‐(2‐HYDROXYETHYL)ETHOXY]PIPERAZINE, 99 %
2.3.3.8.1 Process Description
Into reactor, charge 818 Kg Water and 495 Kg piperazine at room temperature. Add 238 kg 2‐chloroethoxyethanol at 60 °C in 180 minutes. Stir for 12 hrs at 70 °C and monitor the reaction performance by analytical method. After completion of reaction, add 77 kg sodium hydroxide and 715 lit methanol and stirr for 3 hours. Filter the inorganic solid. Distilled out methanol, water, excess piperazine and finally product under high vaccum. Expected weight is 300 Kg. 2.3.3.8.2 Chemical Reaction
2.3.3.8.3 Material Balance
Total number of batches: 10 numbers
Input Qty in kg Output Qty in kg
2‐Chloroethoxyethanol 238 1‐[2‐(2‐Hydroxyethyl)ethoxy]‐piperazine
300
Piperazine 495 Recovered Piperazine 330
Water 818 Sodium chloride 112
Sodium hydroxide 77 Water 818
Methanol 715 Water generated from reaction 35
Recovered Methanol 691
Methanol Loss 24
Distillation Residue 33
Total 2343
Total 2343
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 12
N NH
Cl
Br Cl
N
Cl
N Cl.HCl
1-(3-Chloropropyl)-4-(3-Chlorophenyl)piperazine hydrochloride
Sodium hydroxide
TolueneConc. HCl , Isopropyl alcohol
1-(3-Chlorophenyl)piperazine(M.W. 196.68)
1-Bromo-3-chloropropane(M.W. 157.44)
(M.W. 40.00)
(M.W. 36.5)
2.3.3.9 1‐(3‐CHLOROPROPYL)‐4‐(3‐CHLOROPHENYL)PIPERAZINE HYDROCHLORIDE, 98 %
2.3.3.9.1 Process Description
Charge 414 Kg 1‐(3‐Chlorophenyl) piperazine, 829 kg water and 84 kg sodium hydroxide at
room temperature into clean reactor. Add 1‐Bromo‐3‐chloropropane 332 kg in 2 hrs at 30‐40
°C. Raise the temperature up to 70 deg C. Monitor the reaction performance by analytical
methods. After completion of reaction, cool the mass to 25 to 30 °C and add toluene 1657 lit,
filter the inorganic product (sodium bromide). From the filtrate separate organic layer and
distilled toluene under vaccum. After distillation of toluene add 1243 lit Isopropanol and conc.
HCl (30%) 256 kg under cooling. Cool to 15 °C. Centrifuge the product and dry the product
under vacuum. Filtrate taken for the solvent recovery. Unload and dry the material at 45 to 50
°C in vacuum tray drier (VTD) till to reach the required LOD (Loss on Drying) of the product.
Expected weight is 245 Kg.
2.3.3.9.2 Chemical Reaction
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 13
2.3.3.9.3 Material Balance
Total number of batches: 20 numbers
Input Qty in kg Output Qty in kg
1‐(3‐Chlorophenyl)piperazine 414 1‐(3‐Chloropropyl)‐4‐(3‐chloroph‐enyl)piperazine HCl 98 %
600
1‐Bromo‐3‐chloropropane 332 Sodium bromide 217
Water 829 Water 1008
Sodium hydroxide 84 Water generated from reaction 38
Conc. HCl (30%) 256 Recovered toluene 1491
Isopropyl alcohol 1243 Toluene Loss 166
Toluene 1657 Recovered IPA 1118
IPA Loss 124
Distillation Residue 52
Total 4814
Total 4814
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 14
2.3.3.10 1‐(2‐METHOXYPHENYL) PIPERAZINE HYDROCHLORIDE, 98 %
2.3.3.10.1 Process Description
Into reactor, charge 313 Kg water, 127 Kg o‐anisidine, 184 Kg Bis(2‐Chloroethyl)amine hydrochloride and 123 Kg sodium hydroxide at room temperature. Take temperature 90 °C within 15 hours. Monitor the reaction performance by analytical method. After completion of reaction cool to 35 °C and add 916 lit Toluene at 35 °C in 2 hrs. Stirr for 1 hrs and filter the sodium chloride (inorganic salts) slurry and collect the filtrate separately. Separate organic layer and take for the solvent recovery. After solvent recovery add isopropyl alcohol 380 lit, and IPA.HCl 171 kg under cooling. Stirr for 3 hours. Centrifuge the product and dry the product under vacuum. Filtrate taken for the solvent recovery. Unload and dry the material at 45 to 50 °C in vacuum tray drier (VTD) till to reach the required LOD (Loss on Drying) of the product. Expected weight is 200 Kg.
2.3.3.10.2 Chemical Reaction
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 15
2.3.3.10.3 Material Balance
Total number of batches: 10 numbers
Input Qty in
kg Output Qty in kg
o‐Anisidine 127 1‐(2‐Methoxyphenyl)piperazine HCl
200
Bis(2‐Chloroethyl)amine Hydrochloride
184 Sodium chloride 180
Water 313 Water 314
Sodium hydroxide 123 Water generated from reaction 56
Toluene 380 Recovered toluene 367
IPA.HCl 171 Toluene loss 13
Isopropyl alcohol 380 Recovered IPA 479
Isopropyl alcohol Loss 34
Distillation Residue 35
Total 1678
Total 1678
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 16
2.3.3.11 ISOVALERYL CHLORIDE, 98 %
2.3.3.11.1 Process Description
Into reactor, charge 305 Kg Thionyl chloride and 262 Kg Isovaleric acid at room temperature. Heat the mass to 90 °C and reflux for 10 hrs. During reaction evolution of hydrochloric acid and sulphur dioxide gas scrub with water and caustic solution respectively. After 10 hours monitor the reaction performance by analytical methods. After completion of reaction distilled out the product under vaccum. Expected weight is 300 Kg
2.3.3.11.2 Chemical Reaction
2.3.3.11.3 Material Balance
Total Number of batches: 5 numbers
Input Qty in kg Output Qty in kg
Isovaleric acid 262 Isovaleryl chloride 300
Thionyl chloride 305 Hydrochloric acid 94
Sulphur Dioxide 164
Distillation Residue 9
Total 567
Total 567
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 17
2.3.3.12 2‐METHOXYBENZYLAMINE, 98 %
2.3.3.12.1 Process Description
Into pressure reactor, charge 1335 liter Methanol, 167 Kg ammonia, 13 Kg Raney Ni and 267 Kg 2‐Methoxybenzaldehyde at room temperature. Flush reactor with nitrogen, take pressure of hydrogen 3 kg/cm2 and take temp of 50‐60 °C. Pass hydrogen gas till consumption is going on. After hydrogen consumption completed, Monitor the reaction performance by analytical methods. After completion of reaction cool to room temperature and Filter the reaction mixture and separate Raney Ni. Collect the Mother Liquor and do the distillation of the mix. Initially ammonia scrub through scrubber. Distilled methanol and finally product under high vaccum. Expected weight is 250 Kg.
2.3.3.12.2 Chemical Reaction
2.3.3.12.3 Material Balance
Total Number of batches: 2 numbers
Input Qty in kg Output Qty in kg
2‐Methoxybenzaldhyde 267 2‐Methoxybenzylamine 250
Ammonia gas 167 Recovered ammonia 127
Raney Nickel 13 Ammonia loss 6.5
Hydrogen gas 4 Recovered Raney Ni 13
Methanol 1335 Recovered methanol 1268
Methanol Loss 67
Distillation Residue 19
Water generated from reaction 35.5
Total 1786
Total 1786
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 18
2.3.3.13 1‐BENZYL‐4‐PIPERIDONE, 98 %
2.3.3.13.1 Process Description
Into reactor, charge 803 lit Methanol, 268 Kg Methyl acrylate and 167 Kg Benzylamine at room
temperature. Heat the mass to 45 °C and stir for 10 hrs at 45‐50 °C. Monitor the reaction
performance by analytical methods. After completion of reaction, distilled out methanol under
vacuum till the pot temp reaches 80 °C. Cool reaction mass to room temperature. Add 2171 lit
Xylene and 84 kg sodium methoxide under cooling. Heat slowly and maintain temp 70 °C for 10
hours. Monitor the reaction performance by analytical methods. After completion of reaction,
add conc. HCl (30%) 378 kg, water 28 kg, and stir for 2 hr at the 35 °C. Separate the aqueous
layer and remove Xylene layer. Xylene layer taken for the distillation. And aqueous layer is
basify with 107 kg potassium carbonate and extract product in 1303 lit toluene. After extraction
distill toluene and finally product under full vacuum.Expected weight is 250 Kg.
2.3.3.13.2 Chemical Reaction
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 19
2.3.3.13.3 Material Balance
Total Number of batches: 8 numbers
Input Qty in kg Output Qty in kg
Benzylamine 167 1‐Benzyl‐4‐piperidone 250
Methyl acrylate 268 Recovered Methanol 763
Methanol 803 Methanol Loss 40
Sodium methoxide 84 Sodium chloride 91
Xylene 2171 Methanol generated from reaction 149
Conc. HCl (30%) 378 Carbon dioxide 68
Potassium carbonate 107 Potassium chloride 116
Toluene 1303 Water 279
Water 28 Carbon dioxide from carbonate 34
Recovered Xylene 2062
Xylene loss 109
Recovered toluene 1237
Toluene loss 65
Distillation residue 44
Total 5307
Total 5307
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 20
Veratraldehyde
OH
OCH3
CHO(CH3)2SO4
OCH3
CHO
OCH3
Vanillin
Dimethyl sulphate
Veratraldehyde
(M.W. 152.15)
(M.W. 126.13)
(M.W. 166.18)
2.3.3.14 VERATRALDEHYDE, 98 %
2.3.3.14.1 Process Description
Into reactor, charge 731 lit Dichloromethane, 64 Kg Sodium hydroxide, 12 Kg Tetrabutylammonium bromide, 64 kg water at room temperature. Raise the temperature to 50 °C and add 202 kg dimethyl‐ sulphate slowly within 5‐6 hours. Stir for additional 3 hours. Monitor the reaction performance by analytical methods. After completion of reaction, cool to room temperature and Filter the mass and separate inorganic salt. From filtrate separate organic layer. Take organic layer for distillation and distill dichloromethane and finally product under full vacuum. Expected weight is 250 Kg.
2.3.3.14.2 Chemical Reaction
2.3.3.14.3 Material Balance
Total Number of batches: 2 numbers
Input Qty in
kg Output Qty in kg
Vanillin 244 Veratraldehyde 250
Dimethyl sulphate 202
Dichloromethane 731 Methane sulfonic acid sodium salt 215
Sodium hydroxide 64 Recovered dichloromethane 688
Tetrabutyl ammonium bromide 12 Dichloromethane loss 44
Water 64 Water generated from reaction 29
Water 64
Tetrabutyl ammonium bromide 12
Distillation residue 16
Total 1317
Total 1317
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 21
Cl O
AlCl3
3-Phenylpropionyl chloride
Anhydrous aluminium chloride
Dichloromethane
Sodium hydroxide
O
HCl
(M.W. 168.62)
(M.W. 133.34)
(M.W. 40)
1-Indanone (M.W. 132.16)
Hydrochloric acid(M.W. 36.5)
2.3.3.15 1‐INDANONE, 98 %
2.3.3.15.1 Process Description
Charge 1358 Lit dichloromethane at room temperature into clean reactor. Add 274 kg aluminium chloride and 339 kg 3‐phenylpropionyl chloride in 8 hours at 20‐30 °C. Raise the temperature up to 40 °C and maintain reaction for 5‐6 hours. Monitor the reaction performance by analytical methods. After completion of reaction, cool the mass to 5 to 10 °C and add mixture of 25 kg conc. Hydrochloric acid (30%) and 1018 lit water in to reaction mix under stirring. Separate the organic layer and distilled out dichlomethane up to 60 °C at atmospheric pressure and finally apply full vaccum to distilled out product. Expected weight is 250 Kg.
2.3.3.15.2 Chemical Reaction
2.3.3.15.3 Material Balance
Total Number of batches: 8 numbers
Input Qty in kg Output Qty in kg
3‐Phenylpropionyl chloride 339 1‐Indanone 250
Aluminium chloride anhydrous 274 Aluminium chloride 274
Dichloromethane 1358 Water 1018
Water 1018 Conc. HCl 25
Conc. (30%) 25 Recovered Dichloromethane 1312
Dichloromethane Loss 45
Hydrochloric acid gas 73
Distillation residue 16
Total 3013
Total 3013
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 22
F NH2NH.HCl
Cl
Cl4-FluoroanilineBis(2-Chloroethylamine)hydrochloride(M.W. 111.12)
(M.W. 178.49)
Sodium hydroxide
Toluene
N NHF NaCl
1-(4-Fluorophenyl)piperazineSodium chloride
(M.W. 40.00)
(M.W. 180.23)(M.W. 58.46)
2.3.3.16 1‐(4‐FLUOROPHENYL) PIPERAZINE, 98 %
2.3.3.16.1 Process Description
Into reactor, charge 458 Kg water, 178 Kg 4‐Fluoroaniline, 258 Kg Bis(2‐Chloroethyl)amine hydrochloride and 192 Kg sodium hydroxide at room temperature. Take temperature 90 °C with in 15 hours. Monitor the reaction performance by analytical method. After completion of reaction cool to 35 °C and add 533 lit Toluene at 35 °C in 2 hrs. Stirr for 1 hrs and filter the sodium chloride (inorganic salts) slurry and collect the filtrate separately. Separate organic layer and take for the solvent recovery. After solvent recovery finally apply full vacuum to distill final product 1‐(4‐Fluorophenyl)piperazine. Expected weight is 251 Kg.
2.3.3.16.2 Chemical Reaction
2.3.3.16.3 Material Balance
Total Number of batches: 2 numbers
Input Qty in kg Output Qty in kg
4‐Fluoroaniline 178 1‐(4‐Fluorophenyl)piperazine 251
Bis‐(2‐chloroethyl)amine hydrochloride 285 Sodium chloride 280
Water 458 Water 458
Sodium hydroxide 192 Water generated from reaction 86
Toluene 533 Recovered tolune 515
Toluene loss 18
Distillation Residue 37
Total 1644
Total 1644
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 23
HN COOHO
O O
COOHNO CH3COOH
Isonipecotic acid Acetic anhydride
N-Acetyl-4-piperidinecarboxylic acidAcetic acid
(M.W. 129.16) (M.W. 102.09)
(M.W. 171.20)(M.W. 60.05)
2.3.3.17 N‐ACETYL‐4‐PIPERIDINECARBOXYLIC ACID, 99 %
2.3.3.17.1 Process Description
Into reactor, charge 1218 lit water and 406 Kg Isonipecotic acid at room temperature. Add 321
Kg acetic anhydride at 30 °C in 3‐4 hours. Stir for 20 hrs at 30 °C and monitor the reaction
performance by analytical method. After completion of reaction, Filter the slurry and collect the
Mother Liquor separately. Unload and dry the material at 65 °C in vacuum tray drier (VTD) till to
reach the required LOD (Loss on Drying) of the product. Expected weight is 501 Kg.
2.3.3.17.2 Chemical Reaction
2.3.3.17.3 Material Balance
Total Number of batches: 2 numbers
Input Qty in kg Output Qty in kg
Isonipecotic Acid 406 N‐Acetyl‐4‐piperidinecarboxylic acid 501
Acetic anhydride 321 Acetic acid 189
Water 1218 Water 1218
Distillation Residue 38
Total 1945
Total 1945
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 24
Cl
O
Cl
OH
NaBH4
Methanol
Sodium hydroxide
4'-Chlorobenzopheone
Sodium borohydride
4'-Chlorobenzhydrol
(M.W. 216.67)
(M.W. 40)
(M.W. 37.83)
(M.W. 218.68)
2.3.3.18 4'‐CHLOROBENZHYDROL, 98 %
2.3.3.18.1 Process Description
Into reactor, charge 800 lit methanol, 267 Kg 4’‐chlorobenzophenone at room temperature. Add solution of 12 kg sodium borohydride, 83 lit water and 13 kg sodium hydroxide with in 4‐5 hours. Than stirr the reaction mixture for about 5‐6 hours at 40 °C. Monitor the reaction performance by analytical method. After completion of reaction distilled methanol under vaccum and than add 800 lit. toluene, stirr for 6 hours. Separate the toluene layer and distilled toluene under vaccum and finally product under high vacuum. Expected weight is 250 Kg.
2.3.3.18.2 Chemical Reaction
2.3.3.18.3 Material Balance Total Number of batches: 2 numbers
Input Qty in kg Output Qty in kg
4'‐Chlorobenzophenone 267 4'‐Chlorobenzhydrol 250
Sodium borohydride 12 Sodiumborate 26
Methanol 800 Water 67
Sodium hydroxide 13 Sodium hydroxide 13
Water 83 Recovered toluene 752
Toluene 800 Toluene loss 48
Recovered methanol 752
Methanol loss 48
Distillation Residue 19
Total 1973
Total 1973
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 25
2.3.3.19 HEPTYLAMINE, 99 %
2.3.3.19.1 Process Description
Into pressure reactor, charge 1332 liter Methanol, 199 Kg ammonia, 13 Kg Raney Ni and 266 Kg Heptaldehyde at room temperature. Flush reactor with nitrogen, take pressure of hydrogen 3 kg/cm2 and take temp of 50‐60 °C. Pass hydrogen gas till consumption is going on. After hydrogen consumption completed, Monitor the reaction performance by analytical methods. After completion of reaction cool to room temperature and Filter the reaction mixture and separate Raney Ni. Collect the Mother Liquor and do the distillation of the mix. Initially ammonia scrub through scrubber. Distilled methanol and finally product under high vaccum. Expected weight is 250 Kg.
2.3.3.19.2 Chemical Reaction
2.3.3.19.3 Material Balance Total Number of batches: 20 numbers
Input Qty in kg Output Qty in kg
Heptaldehyde 266 Heptylamine 250
Ammonia 199 Recovered ammonia 151
Raney Ni 13 Ammonia Loss 8
Methanol 1332 Recovered Raney Ni 13
Hydrogen 5 Recovered methanol 1266
Methanol loss 67
Water generated from reaction 42
Distillation residue 19
Total 1815
Total 1815
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 26
CH2Cl NaO NO2
CH2 O NO2
MonoethyleneglycolToluene
CH2 O NH2.HCl
4-Benzyloxyaniline Hydrochloride
4-Benzyloxynitrobenzene
Benzyl chloride p-Nitrophenol sodium sal
(M.W. 229)
(M.W. 235.71)
(M.W. 126.56) (M.W. 161.00)
HydrogenMethanol Raney Ni
2.3.3.20 4‐BENZYLOXYANILINE HCL, 98 %
2.3.3.20.1 Process Description
Into the reactor charge 205 Kg p‐Nitrophenol sodium salt and 242 lit Monoethyleneglycol at room temperature. Add 161Kg Benzyl chloride and 483 lit. toluene into the mass in 7 hrs at 70 °C. Cool to 50 °C and stir for 12 hrs. Monitor the reaction performance by analytical methods. After completion of reaction cool the mass to room temperature. Into the mass add 483 Kg Water and separate the layers and distill out toluene from organic layer completely at below 70 °C under vaccum. Reaction mass transfer in to pressure reactor and add 1026 lit Methanol and 13 kg Raney Ni under nitrogen. Heat the mix up to 50 °C and Pass hydrogen gas take pressure 3 kg/cm2. And continued till consumption is going on. After hydrogen consumption completed, Monitor the reaction performance by analytical methods. After completion of reaction cool to room temperature and Filter the reaction mixture and separate Raney Ni. Collect the Mother Liquor and add 136 kg conc. HCl (30%) under stirring. Stirr for 2 hours and filter the product. Unload and dry the material at 45 to 50 °C in vacuum tray drier (VTD) till to reach the required moisture content of the product. Expected weight is 250 Kg.
2.3.3.20.2 Chemical Reaction
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 27
2.3.3.20.3 Material Balance Total Number of batches: 2 numbers
Input Qty in kg Output Qty in kg
Benzyl chloride 161 4‐Benzyloxyaniline hydrochloride 250
p‐Nitrophenol sodium salt 205 Sodium chloride 75
Monoethyleneglycol 242 Recovered toluene 454
Toluene 483 Water 579
Water 483 Toluene loss 29
Methanol 1026 Monoethylene glycol 242
Raney Ni 13 Recovered Raney Ni 13
Hydrogen 7 Water from reaction 41
Conc. HCl (30%) 136 Recovered methanol 954
Methanol loss 72
Distillation Residue 49
Total 2755
Total 2755
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 28
O O
O OBr Br
NaOC2H5
Toluene
Diethyl malonate1,3-Dibromopropane
Sodium ethoxide(M.W. 68.05)
(M.W. 160.08)(M.W. 201.89)
COOC2H5
COOC2H5
Diethyl 1,1--cyclobutanedicarboxylate Potassium hydroxideKOH
(M.W. 56.11)Methanol, Conc. HCl, Ethyl acetate
COOHCO2
Cyclobutanecarboxylic acidCarbon dioxide
(M.W. 200.24)
(M.W. 100.12)(M.W. 46.00)
2.3.3.21 CYCLOBUTANECARBOXYLIC ACID, 98 %
2.3.3.21.1 Process Description
Into reactor, charge 1535 Kg Toluene, 512 Kg Diethyl malonate, 645 Kg and 1,3‐Dibromopropane at room temperature. Raise the temperature to 50 °C and add 435 kg sodium ethoxide under stirring with in 12 hr at 50‐60 °C. After addition stirr for additional 4 hours. Monitor the reaction performance by analytical methods. After completion of reaction, filter the product and distill out toluene form filtrate under vaccum till pot temp 75 deg C. In the reaction mass add 1632 lit methanol. Take temp up to 50 °C, add 359 kg potassium hydroxide within 4‐5 hours. Reflux the mix for 3 hours. Monitor the reaction performance by analytical methods. After completion of reaction, distill out methanol till pot temp 80 °C under vacuum. Add 1632 lit ethyl acetate in to the mix. Cool the mixture up to 25 °C and add 661 kg conc. HCl (30%). Separate the organic layer and distilled out ethyl acetate and than heat the mix till pot temp 130‐140 °C, during this decarboxylation is going on. After decarboxylation distilled product under vaccum. Expected weight is 250 Kg.
2.3.3.21.2 Chemical Reaction
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 29
2.3.3.21.3 Material Balance
Total Number of batches: 2 numbers
Input Qty in kg Output Qty in kg
Diethyl malonate 512 Cyclobutanecarboxylic acid 250
1,3‐Dibromopropane 645 Sodium bromide 658
Sodium ethoxide 435 Ethyl alchol form reaction 544
Toluene 1535 Recovered toluene 1458
Potassium hydroxide 359 Toluene loss 77
Methanol 1632 Potassium chloride 405
Conc. Hydrochloric acid (30%) 661 Carbon dioxide 120
Ethyl acetate 1632 Water 517
Recovered methanol 1542
Methanol loss 90
Recovered Ethyl acetate 1526
Ethyl acetate loss 106
Distillation Residue 118
Total 7408
Total 7408
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 30
O O
O OBr
Br
NaOC2H5
Toluene
Diethyl malonate
Sodium ethoxide(M.W. 68.05)
(M.W. 160.08)
1,4-Dibromobutane
COOC2H5
COOC2H5
(M.W. 215.92)
Diethyl 1,1-cyclopentanedicarboxylate(M.W. 214.26)
2.3.3.22 DIETHYL CYLOPENTANCEABOXYLATE, 98 %
2.3.3.22.1 Process Description
Into reactor, charge 1535 Kg Toluene, 215 Kg Diethyl malonate, 290 Kg and 1,4‐Dibromobutane
at room temperature. Raise the temperature to 50 °C and add 183 kg sodium ethoxide under
stirring with in 12 hr at 50‐60 °C. After addition stirr for additional 4 hours. Monitor the reaction
performance by analytical methods. After completion of reaction, filter the inorganic salt and
distill out toluene form filtrate under vaccum till pot temp 75 °C. And finally apply full vacuum,
distilled the product. Expected weight is 250 Kg.
2.3.3.22.2 Chemical Reaction
2.3.3.22.3 Material Balance Total Number of batches: 2 numbers
Input Qty in kg Output Qty in kg
Diethyl malonate 215 Diethyl 1,1‐cyclopentanedicarboxylate, 98% 250
1,4‐Dibromobutane 290 Sodium bromide 277
Sodium ethoxide 183 Ethanol from reaction 124
Toluene 645 Recovered toluene 613
Toluene loss 32
Distillation residue 38
Total 1333
Total 1333
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 31
NH2 NaNO2
Conc. HCl
KI
Toluene
I
1-Naphthylamine
Sodium Nitrate Potassium iodide
1-Iodonapthalene
(M.W. 143.00) (M.W. 254.07)
2.3.3.23 1‐IODONATHALENE, 98 %
2.3.3.23.1 Process Description
Into reactor, charge 715 Kg conc. HCl (30%) at room temperature. Then add 168 Kg
1‐Napthylamine in 30 minutes at room temperature. Cool the mass to 0‐5 °C, add 81 kg sodium
nitrate slowly under stirring with in 3‐4 hours. And stir for 4 hrs at the same temperature.
Monitor the diazotization reaction performance by analytical methods. After diazotization of
reaction, dump the reaction mix in to mix having 195 kg potassium iodide, 639 lit water and 504
lit. toluene. Stirr the mix at 30 °C. Separate the toluene layer and distilled out toluene under
vaccum and finally the final product under full vacuum. Expected weight is 250 Kg.
2.3.3.23.2 Chemical Reaction
2.3.3.23.3 Material Balance Total Number of batches: 2 numbers
Input Qty in kg Output Qty in kg
1‐Napthylamine 168 1‐Iodonapthalene, 98% 250
Conc. HCl (30%) 715 Conc. HCl 429
Sodium nitrate 81 Nitrogen 33
Potassium iodide 195 Potassium chloride 88
Toluene 504 Sodium chloride 69
Water 639 Water 882
Recovered toluene 477
Toluene loss 28
Distillation Residue 48
Total 2302
Total 2302
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 32
ClHN N
Sodium hydroxide
MEKImidazoleAllyl chloride(M.W. 76.56) (M.W. 68.08)
(M.W. 40)N
N
1-Allylimidazole(M.W. 108.14)
2.3.3.24 1‐ALLYL IMIDAZOLE, 98 %
2.3.3.24.1 Process Description
Into reactor, charge 104 Kg water, 104 Kg Sodium hydroxide and 177 Kg Imidazole at room
temperature. Raise the temperature to 40 °C and add 199 kg Allyl chloride with in 5‐6 hours.
Stir for 6 hours at 40 °C. Monitor the reaction performance by analytical methods. After
completion of reaction, cool to room temperature and add 597 lit MEK, stir for 20 min.
Separate the organic layers. Take organic layer for distillation, first remove MEK under vaccum
and finally distilled out product under high vacuum. Expected weight is 250 Kg.
2.3.3.24.2 Chemical Reaction
2.3.3.24.3 Material Balance Total Number of batches: 1 numbers
Input Qty in kg Output Qty in kg
Allyl chloride 199 1‐Allylimidazole, 97% 250
Imidazole 177 Sodium chloride 152
Sodium hydroxide 104 Recovered MEK 558
Water 104 MEK Loss 39
MEK (Methyl ethy ketone) 597 Water 151
Distillation Residue 31
Total 1181
Total 1181
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 33
NH2
NH2
NH2 NH2
O
NH
NHO
POCl3
NaOH NH
NCl
o-Pheneylenediamine Carbamide
Xylene
Benzimidadazol-2-one
Phosphorus oxychloride
Sodium hydroxide2-Chlorobenzimidazaole
(M.W. 108.14) (M.W. 60.06)
(M.W. 134.14)
(M.W. 153.33)
(M.W. 40.00) (M.W. 152.58)
2.3.3.25 2‐CHLOROBENZIMIDAZOLE, 98 %
2.3.3.25.1 Process Description
Into reactor, charge 1022 Kg Xylene, 255 Kg o‐Phenylenediamine and 142 Kg carbamide at
room temperature. Heat the mass to 130 °C and stir for 8 hrs at reflux temperature. Monitor
the reaction performance by analytical methods. After completion of reaction cool to 20 °C
temperature and stir for 2 hr at the same temperature. Filter the slurry. Collect the Mother
Liquor and take for recovery i.e. Xylene distillation. Unload and dry the material at 60 °C in tray
drier till to reach the required LOD (Loss on Drying) of the product. Expected weight is 311 Kg.
Unload the material from dryer and charge into clean reactor. Add 355 Kg phosphorus
oxychloride and heat to 90 °C. Stir for 15 at 90 °C. Cool the mass and dump in to 1863 lit water
below 40 °C. After dumping take pH neutral using 555 kg sodium hydroxide and than extract in
to chloroform. Separate the organic layer and distilled out chloroform. Filter the slurry dry in
tray dryer till to reach the required LOD (Loss on Drying) of the product. Expected weight is 300
Kg.
2.3.3.25.2 Chemical Reaction
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 34
2.3.3.25.3 Material Balance
Total Number of batches: 5 numbers
Input Qty in kg Output Qty in kg
o‐Phenylenediamine 255 2‐Chlorobenzimidazole, 97% 300
Carbamide 142 Ammonia gas 80
Xylene 1022 Recovered Xylene 988
Phosphorus oxychloride 355 Xylene loss 34
Chloroform 931 Recovered chloroform 880
Water 1863 Chloroform loss 51
Sodium hydroxide 555 Water 1945
Sodium phosphate tribasic 379
Sodium chloride 406
Distillation residue 59
Total 5123
Total 5123
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 35
Cl
CN Br Br
KOH
Cat. TBAB
Toluene
Potassium hydroxide
1,3-Dibromopropane4-Chlorobenzylcyanide
Cl
CN
1-(4-Chlorophenyl)cyclobutanecarbonitrile
(M.W. 151.60)(M.W. 201.89)
(M.W. 56.11)
(M.W. 191.66)
2.3.3.26 1‐(4‐CHLOROPHENYL)CYCLOBUTANECARBONITRILE, 98 %
2.3.3.26.1 Process Description
Into reactor, charge 667 lit Toluene, 222 Kg 4‐Chlorobenzylcyanide, 296 Kg and 1,3‐Dibromopropane at room temperature. Raise the temperature to 50 °C and add 194 kg potassium hydroxide under stirring with in 12 hr at 50‐60 °C. After addition stirr for additional 4 hours. Monitor the reaction performance by analytical methods. After completion of reaction, filter the inorganic salt and distill out toluene form filtrate under vaccum till pot temp 75 °C. And finally apply full vacuum, distilled the product. Expected weight is 250 Kg.
2.3.3.26.2 Chemical Reaction
2.3.3.26.3 Material Balance
Total Number of batches: 4 numbers
Input Qty in kg Output Qty in kg
4‐Chlorobenzyl cyanide 222 1‐(4‐Chlorophenyl)cyclobutanecarbonitrile, 97% 250
1,3‐Dibromopropane 296 Potassium bromide 349
Potassium hydroxide 194 Recovered cat. TBAB 11
Water 194 Recovered toluene 634
Cat. TBAB 11 Toluene loss 33
Toluene 667 Water 275
Distillation residue 31
Total 1583
Total 1583
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 36
OH Br2
Ethylenedichloride
OH
Br
Cuprous CyanideCuCNDMF
OH
CN
2,6-Dimethylphenol2,6-Dimethyl-4-bromopheno
2,6-Dimethyl-4-cyanophenol
(M.W. 122.17)(M.W. 201.00)
(M.W. 159.81)
(M.W. 89.56)
(M.W. 147.17)
2.3.3.27 3,5‐DIMETHYL‐4‐CYANOPHENOL, 98 %
2.3.3.27.1 Process Description
Into reactor, charge 797 Kg Ethylene dichloride and 266 Kg 2,6‐dimethylphenol at room
temperature. Then add 347 Kg Bromine in 6‐7 hours at 40. Stirr the reaction mix for 6‐7 hours.
Monitor the reaction performance by analytical methods. After completion of reaction, heat
the mass distilled out ethylene dichloride under vacuum till pot temp reaches 70 °C. Add 804 kg
dimethyl formamide and 179 kg cuprous cyanide heat the reaction mix up to 90‐100 °C. And
maintain for 8‐10 hours. Monitor the reaction performance by analytical methods. After
completion of the reaction, distilled dimethyl formamide under vaccum till pot temp 100 °C.
Add 1206 lit water and maintain temp 50‐60 deg , till reaction mixture completely decompose.
Filter the slurry and collect the Mother Liquor separately. Unload and dry the material at 65 °C
in vacuum tray drier (VTD) till to reach the required LOD (Loss on Drying) of the product.
Expected weight is 420 Kg.
2.3.3.27.2 Chemical Reaction
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 37
2.3.3.27.3 Material Balance
Total Number of batches: 2 numbers
Input Qty in kg Output Qty in kg
2,6‐Dimethylphenol 266 3,5‐Dimethyl‐4‐cyanophenol, 98% 250
Bromine 347 Hydrobromic acid (gas) 176
Ethylene dichloride 797 Recovered Ethylene dichloride 757
Cuprous cyanide 179 Ethylene dichloride loss 40
Dimethyl formamide 804 Recovered dimethyl formamide 748
Water 1206 Dimethyl formamide loss 57
Cuprous bromide 287
Water 1206
Distillation residue 79
Total 3597
Total 3597
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 38
CH2 N
O
.HCl
5% Pd on carbon
MethanolHydrogen
.HClN
O
H
1-Benzyl-3-piperidone hydrochloride (3-Piperidone hydrochloride)
Di-tert-butylcarbonate
Sodium hydroxideNaOH
N
O
O
O
1-Boc-3-piperidone(M.W. 199.25)
(M.W. 225.72)
(M.W. 40.00)
(M.W. 218.15)
2.3.3.28 1‐BOC‐3‐PIPERIDONE, 97 %
2.3.3.28.1 Process Description
Into pressure reactor, charge 1593 litre Methanol, 16 kg 5% on palladium on carbon and 319 kg
1‐Benzyl‐3‐piperidone hydrate hydrochloride under nitrogen at room temperature. Flush
reactor with nitrogen, take pressure of hydrogen 3 kg/cm2 and take temp of 50‐60 °C. Pass
hydrogen gas till consumption is going on. After hydrogen consumption completed, Monitor
the reaction performance by analytical methods. After completion of reaction cool to room
temperature and Filter the reaction mixture and separate 5% Pd on carbon. Filtrate cool to 0‐5
°C and add 57 kg sodium hydroxide below 5 °C, followed by addition of di‐tert‐butyldicarbonate
with in 4‐5 hours. Monitor the reaction performance by analytical methods. After completion
add 16 kg activated carbon filter the inorganic solid. Distilled methanol under vacuum till pot
temp 60 °C and than collected main product using high vacuum distillation. Expected weight is
250 Kg.
2.3.3.28.2 Chemical Reaction
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 39
2.3.3.28.3 Material Balance
Total Number of batches: 2 numbers
Input Qty in kg Output Qty in kg
1‐Benzyl‐3‐piperidone hydrate hydrochloride 319 1‐Boc‐3‐piperidone, 97% 250
5% Pd on carbon 16 tert‐Butanol 105
Methanol 1593 Carbon dioxide 62
Hydrogen 3 Recovered 5% on carbon 16
Activated carbon 16 Sodium chloride 83
Di‐tert‐butyldicarbonate 308 Water 26
Sodium hydroxide 57 Recovered Methanol 1513
Methanol loss 80
Toluene 130
Distillation Residue 31
Recovered activated carbon 16
Total 2311
Total 2311
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 40
1-(3-Chloropropyl)-1,3-dihydro-2H-benzimidazol-2-one
NH2
NH2
O
O ONH
NO
NO
N
Cl
ON
Cl
NH
Xylene
o-Phenylenediamine Methylacetoacetate
(M.W. 108.14) (M.W. 116.12) Stage-1
Stage-21-(3-Chloropropyl)-1,3-dihydro-2H-benzimidazol-2-one
Br Cl1-Bromo-3-chloropropane
(M.W. 157.44)
NaOH(M.W. 40)
Cat. TBAB
Methanol
Conc. HCl
(M.W. 174.20)
(M.W. 210.66)
2.3.3.29 1‐(3‐CHLOROPROPYL)‐2‐BENZIMIDAZOLIDINONE, 98 %
2.3.3.29.1 Process Description
Into reactor, charge 824 lit Xylene, 206 Kg o‐Phenylenediamine and 221 Kg Methylacetoacetate at room temperature. Heat the mass to 135‐140 °C and remove water and methanol by azeotropic distillation within 8‐10 hours. Maintain the same temp till water‐methanol mixture completely remove. Monitor the reaction performance by analytical methods. After completion of reaction cool to 10 °C and stir for 2 hr at the same temperature. Filter the slurry. Dry the material. Weight of the material is 282 kg. Charge 282 kg material into clean reactor. 255 kg 1‐Bromo‐3‐chloropropane, 282 lit water, 65 kg sodium hydroxide, 14 kg cat. TBAB and 846 lit toluene. Heat to 50 °C. Monitor the reaction performance by analytical methods. After completion of reaction cool to room temperature and stir for 2 hr at the same temperature. Filter the slurry and separate the aqueous layer. Distilled off toluene under vaccum till pot temp. 60 °C. Cool the mix to room temp add 846 lit methanol and 197 kg conc. HCl (30%), heat the mix up to 50 °C, and stirr for 4 hours. Monitor the reaction performance by analytical methods. After completion of reaction cool to 5 °C and stirr at 5 °C for 2 hours. Filter the slurry. Take filtrate for the recovery of methanol. Unload the material and dry material till to reach the required LOD (Loss on Drying) of the product. Expected weight is 300 Kg.
2.3.3.29.2 Chemical Reaction
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 41
2.3.3.29.3 Material Balance
Total Number of batches: 10 numbers
Input Qty in kg Output Qty in kg
o‐Phenylenediamine 206 1‐(3‐Chloropropyl)‐2‐benzimidazolidinone, 98% 300
Methyl acetoacetate 221 Water 511
Xylene 824 Recovered Xylene 796
1‐Bromo‐3‐chloropropane 255 Xylene loss 28
Water 282 Sodium bromide 166
Sodium hydroxide 65 Recovered Tolune 761
Cat. TBAB 14 Toluene loss 85
Toluene 846 Recovered methanol 822
Conc. HCl (30%) 197 Methanol loss 85
Methanol 846 Isopropanol 97
Cat. TBAB 14
Distillation residue 91
Total 3754
Total 3754
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 42
NH
Toluene Potassium carbonateK2CO3
Cl CN
N
CNPyrrolidine
(M.W. 71.12) 4-Chlorobutyronitrile(M.W. 103.55)
1-Pyrrolidinebutanitrile(M.W. 138.21)
(M.W. 138.21)
2.3.3.30 1‐PYRROLIDINEBUTANENITRILE, 98 %
2.3.3.30.1 Process Description
Into reactor, charge 411 lit Toluene and 137 Kg pyrrolidine at room temperature. Then add 200
kg 4‐chlorobutyronitrile and 133 kg potassium carbonate in 30 minutes at room temperature.
Heat the mass to 70‐80 °C and stirr for 4 hrs at the same temperature. Monitor the reaction
performance by analytical methods. After completion of reaction, filter the inorganic and
distilled toluene under vaccum and finally product under high vaccum. Expected weight is 250
Kg.
2.3.3.30.2 Chemical Reaction
2.3.3.30.3 Material Balance Total Number of batches: 4 numbers
Input Qty in kg Output Qty in kg
Pyrrolidine 137 1‐Pyrrolidinebutanenitrile, 98% 250
4‐Chlorobutyronitrile 200 Potassium chloride 144
Toluene 411 Recovered toluene 370
Potassium carbonate 133 Toluene loss 41
Carbon dioxide 42
Water 17
Distillation residue 16
Total 881
Total 881
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 43
N OO
O
Br ClMg
THF
Cl
MgBr
NO
OOH OH
HN
N-Carbethoxy-4-piperidone 4-Chlorobromobenzen
1-(4-Chlorophenyl)-4-hydroxypiperidin
(M.W. 171.20) (M.W. 191.45)
(M.W. 24.30)
(M.W. 211.69)
KOHPotassium hydroxide
(M.W. 56.11)
HCl(M.W. 36.5)
IPA(Intermediate)
2.3.3.31 1‐(4‐CHLOROPHENYL)‐4‐HYDROXYPIPERIDINE, 98 %
2.3.3.31.1 Process Description
Into the reactor charge 1248 lit Tetrahydrofuran and 35 kg Magnesium turnings under at room
temperature. Heat the mix up to 50 °C. Add 4‐bromo‐1‐chlorobenzene under stirring at 50‐60
°C with in 4‐5 hours. Stirr the reaction mass at this temp for 2 hours. Monitor the reaction
performance by analytical methods. After completion of reaction add N‐Carbethoxy‐4‐
piperidone in to the reaction mix at 40‐50 °C with in 4‐5 hours. Maintain temp 2 hours at 50‐60
°C. Monitor the reaction performance by analytical methods. Cool the mass to room
temperature. Into the mass add 177 lit conc. HCl below 10 °C. Separate the organic layer. Distill
off Tetrahydrofuran under vaccum till pot temp 70 °C. Cool the mass and add 999 lit
Isopropanol and 192 kg potassium hydroxide. Reflux the reaction mass for 12 hours. Monitor
the reaction performance by analytical methods. Cool the reaction mix up to 10 °C. Filter the
slurry. Unload the material and dry material till to reach the required LOD (Loss on Drying) of
the product. Expected weight is 250 Kg.
2.3.3.31.2 Chemical Reaction
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 44
2.3.3.31.3 Material Balance Total Number of batches: 3 numbers
Input Qty in kg Output Qty in kg
N‐Carbethoxy‐4‐piperidone 250 1‐(4‐Chlorophenyl)‐4‐hydroxypiperidine 250
4‐Bromo‐1‐chlorobenzene 279 Recovered Tetrahydrofuran 1148
Magnesium turnings 35 Tetrahydrofuran Loss 100
Tetrahydrofuran 1248 Recovered Isopropanol 929
Conc. HCl (30%) 177 Loss Isopropanol 70
Isopropanol 999 Potassium hydroxide 192
Potassium hydroxide 192 Carbon dioxide 65
Ethanol 68
Water 124
Magnesium bromide hydroxide 177
Distillation residue 59
Total 3181
Total 3181
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 45
2.4 RAW MATERIAL CONSUMPTION, STORAGE AND HANDLING
The raw materials are received in tanks, HDPE/fibre drums, HMHDPE Carboys and cylinders as
well as through tankers and stored at ambient temperature. All the storage tanks of hazardous
flammable substances are located within premises in separate storage area i.e. solvent farm
area at ambient temperature. Solvents like Methanol, Toluene, IPA, Xylene, etc. shall be stored
in undergroungd storage tank with all precautionary process instrumentation and safety
appliances. Large area shall be covered by well‐designed warehouse, which is containing store
office, raw material store, finished product store, etc. The personnel protective equipments like
hand gloves, safety shoes, goggles, helmet, clothing, etc. are provided to those handling
hazardous chemicals as per requirement. All the motors and electrical connections are flame
proof. After proposed expansion, these procedures are following as exsting scenario and
develop additional infrasture as per requirement. List of raw material are given in Table‐2.2.
TABLE ‐ 2.2
RAW MATERIAL REQUIREMENT (EXISTING SCENARIO)
SR.
NO.
RAW MATERIALS QUANTITY
(MT/MONTH)
1‐Benzylpiperazine, 99%
Benzyl chloride 0.072
Piperazine 0.049
Toluene 0.100
1
Sodium hydroxide 0.023
Dibutyl oxalate, 98%
n‐Butanol 0.073
2
Toluene 0.100
1,4‐Piperazinedicarboxaldehyde, 99%
Piperazine 0.076
Formic acid (85%) 0.061
3
Xylene (mix.) 0.100
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 46
1,4‐Dibromobutane, 99%
1,4‐Butanediol 0.042
Hydrobromic acid (48%) 0.156
4
Toluene 0.100
1‐(4‐Fluorophenyl)piperazine, 99%
4‐Fluoroaniline 0.015
Bis(2‐Chloroethylamine)hydrochloride 0.025
Isopropyl alcohol 0.100
5
Potassium carbonate 0.029
1‐Benzyldiethanolamine, 98%
Benzyl chloride 0.033
Diethanolamine 0.027
Methylene dichloride 0.080
6
Sodium carbonate 0.014
TABLE ‐ 2.2 (CONTD.)
RAW MATERIAL REQUIREMENT (PROPOSED SCENARIO)
SR.
NO.
RAW MATERIALS QUANTITY
(MT/MONTH)
1 1,3‐Dibromopropane 2.470
2 1,4‐Dibromobutane 0.580
3 1‐Benzyl‐3‐piperidone hydrate hydrochloride 0.640
4 1‐Bromo‐3‐chloropropane 5.000
5 1‐Napthylamine 0.340
6 2,6‐Dimethylphenol 0.530
7 2‐Chloroethoxyethanol 2.380
8 2‐Methoxybenzaldehyde 0.530
9 3‐Chloroaniline 6.110
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 47
10 3‐Phenylpropionyl chloride 2.720
11 4‐Bromo‐1‐chlorobenzene 0.840
12 4'‐Chlorobenophenone 0.530
13 4‐Chlorobenzyl cyanide 0.890
14 4‐Chlorobutyronitrile 0.800
15 4‐Fluoroaniline 0.360
16 5 % Pd on carbon 0.030
17 Acetic Anhydride 0.640
18 Activated Carbon 0.030
19 Allyl Chloride 0.200
20 Aluminium chloride anhydrous 2.190
21 Ammonia 4.310
22 Benzyl Chloride 0.320
23 Benzylamine 1.330
24 Bis(2‐Chloroethyl)amine Hydrochloride 10.000
25 Bromine 0.690
26 Carbamide 0.710
27 Cat. TBAB 0.190
28 Chloroform 2.000
29 Conc. Hydrochloric Acid (30 %) 10.000
30 Cuprous Cyanide 0.360
31 Dichloromethane 5.000
32 Diethyl Formamide 1.450
33 Dimethyl Malonate 2.000
34 Dimethyl Sulphate 0.400
35 Di‐tert‐butyldicarbonate 0.620
36 Ethyl Acetate 2.000
37 Ethylene dichloride 1.500
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 48
38 Heptaldehyde 5.330
39 Hydrogen Gas 0.120
40 Imidazole 0.180
41 IPA.HCl 1.710
42 Isonipecotic Acid 0.810
43 Isopropyl Alcohol 10.000
44 Isovaleric Acid 1.310
45 Magnesium turnings 0.110
46 MEK (Methyl Ethyl Ketone) 0.600
47 Methanol 20.00
8 Methyl Acetoacetate 2.210
49 Methyl Acrylate 2.140
50 Monoethyleneglycol 0.600
51 N‐Carbethoxy‐4‐piperidone 0.750
52 o‐Anisidine 1.270
53 o‐Phenylenediamine 3.340
54 Phosphorus Oxychloride 1.770
55 Piperazine 4.950
56 p‐Nitrophenol sodium salt 0.410
57 Potassium Carbonate 1.390
58 Potassium Hydroxide 2.070
59 Potassium Iodide 0.390
60 Pyrrolidine 0.550
61 Raney Ni 0.320
62 Sodium Borohydride 0.020
63 Sodium Ethoxide 1.230
64 Sodium Hydroxide 10.000
65 Sodium Methoxide 0.670
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 49
66 Sodium Nitrate 0.160
67 Tetrabutyl ammonium bromide 0.020
68 Tetrahydrofuran 2.000
69 Thionyl Chloride 1.530
70 Toluene 15.000
71 Vanillin 0.490
72 Xylene 5.000
2.4.1 DETAILS OF SOLVENT RECOVERY PLAN
M/s. Allchem Laboratories, Vadodara has adopted standard operating procedure for the
solvent recovery from mother liquor. At M/s. Allchem Laboratories all the solvent/mother
liquors divided in to two categories
Category A: Non‐protic solvent (Chloroform, Dichloromethane, ethylene dichloride, methyl
ethyl ketone, toluene, xylene)
Category B: Protic solvent (Dimethyl formamide, ethyl acetate, isopropyl alchol, methanol,
mono ethylene glycol, Tetrahydrofuran, Acetone)
2.4.1.1 EQUIPMENT AND UTILITIES REQUIREMENT DURING DISTILLATION
• Distillation vessels/reactors is clean and empty.
• It is fully equipped with addition vessels, distillation column length min 1‐2 meter, heating,
primary condenser (cooling tower water circulation), secondary condenser (chilling water
circulation), product cooler (chilling water circulation), receiver & condenser vent
connected to scrubber.
2.4.1.2 IMPORTANT MEASURE TAKES DURING SOLVENT RECOVERY
• Distillation vessels/rectors is perfectly earth to remove any static charge produce during
distillation.
• Maintain temperature constantly
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 50
• Circulation of cooling tower and chilling plant water in condenser without interruption to
avoid solvent loss.
• Heating cut off as soon as rise in standard vapour Temprature.
2.4.1.3 SOLVENT RECOVERY FOR THE CATEGORY A: NON‐PROTIC SOLVENT
(Chloroform, Dichloromethane, Ethylene Dichloride, Methyl Ethyl Ketone, Toluene,
Xylene)
• Transfer solvent/mother liquors from the storage tank / containers (drums) in to the
distillation vessels/reactors using Teflon diaphragm pump using air/nitrogen.
• Start stirring and add 10% v/v solution 1.25 N NaOH solution under stirring to
remove all the acidic impurities. Stirr the mixture for 30 min. After 30 min. stop
stirring and kept for the settling. Separate the aqueous layer.
• Than add 10% v/v solution 1.25 N HCl solution under stirring to remove all the basic
impurities. Stirr the mixture for 30 min. After 30 min. stop stirring and kept for the
settling. Separate the aqueous layer.
• After base and acid wash, again wash organic solvent with 10% v/v with DM water to
remove all the inorganic part which is trap in to the solvent. Stirr for the 30 min. and
separate aqueous layer perfectly.
• Start heating under stirring. Distilled out low boiling cut till vapour temp. of the
solvent reached at standard distillation temperature. Recycled this low boiling cut in
next distillation.
• Check the moisture content and purity. (M/C NMT 0.5% and Purity NLT 99.0%).
Heating, stirring and cooling parameters are continuously maintained till get the
right results.
• After distillation, cool the mass and collect the residue in to the suitable container
from the bottom and send for incineration.
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 51
2.4.1.3 SOLVENT RECOVERY FOR THE CATEGORY B: PROTIC SOLVENT
(Dimethyl Formamide, Ethyl Acetate, Isopropyl Alchol, Methanol, Mono Ethylene
Glycol, Tetrahydrofuran, Acetone)
• Distillation carried out in min. 3‐5 meter distillation column.
• Transfer solvent/mother liquors from the storage tank / containers (drums) in to the
distillation vessels/reactors using Teflon diaphragm pump using air/Nitrogen.
• Start heating under stirring. Distilled out low boiling cut till vapour temp of the
solvent reached at standard distillation temperature. Recycled this low boiling cut in
next distillation.
• Check the moisture content and purity. (M/C NMT 4‐5% and Purity NLT 98.0%).
Heating, stirring and cooling parameters are continuously maintained till get the
right results.
• After distillation, cool the mass and collect the residue in to the suitable container
from the bottom and send for incineration.
List of Solvent along with total recovery is shown in Table‐2.3.
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 52
TABLE ‐ 2.3
LIST OF SOLVENTS ALONGWITH TOTAL RECOVERY
No. Solvent Capacity Total input %
Qty. of Water Actual Qty. Qty. of Loss % % %
Moisture Recovered inputSolvent
RecoveredResidue
Recovered Ltr. Recovery Loss ResidueLtr. Ltr. Ltr. Ltr. Ltr. Ltr.
1 Methanol 20000 20000 8% 1600 18400 17112 1240.16 47.84 93% 0.26% 6.74%2 Toluene 15000 15000 3% 450 14550 13823 692.58 34.92 95% 0.24% 4.76%3 Isopropyl alcohol (IPA) 10000 10000 8% 800 9200 8648 534.52 17.48 94% 0.19% 5.81%4 Dichloromethane (MDC) 5000 5000 3% 150 4850 4462 375.875 12.125 92% 0.25% 7.75%5 Xylene 5000 5000 3% 150 4850 4608 233.285 9.215 95% 0.19% 4.81%6 Chloroform 2000 2000 3% 60 1940 1804 131.92 3.88 93% 0.20% 6.80%7 Ethyl acetate (EA) 2000 2000 6% 120 1880 1767 108.476 4.324 94% 0.23% 5.77%8 Tetrahydrofuran (THF) 2000 2000 8% 160 1840 1711 123.832 4.968 93% 0.27% 6.73%9 Ethylenedichloride (EDC) 1500 1500 4% 60 1440 1368 68.256 3.744 95% 0.26% 4.74%
10 Dimethyl formamide (DMF) 1450 1450 8% 116 1334 1241 90.1784 3.2016 93% 0.24% 6.76%11 Methyl ethlketone (MEK) 600 600 5% 30 570 536 33.003 1.197 94% 0.21% 5.79%12 Monoethylene glycol (MEG) 600 600 10% 60 540 491 47.358 1.242 91% 0.23% 8.77%13 Acetone 1000 1000 7% 70 930 865 62.589 2.511 93% 0.27% 6.73%
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 53
2.5 INFRASTRUCTURE FACILITIES
2.5.1 LAND
The land area occupied by M/s. Allchem Laboratories is about 1,125 m2 as existing scenario and
after proposed expansion is about total 8,189 m2. Provisions are made for administrative
building, laboratory, plant area, hazardous waste storage area, effluent treatment plant,
environment analysis lab, chemical storage area, utilities area, security area, vehical parking,
etc. The proposed project activities will take place in the company premises. The break up of
total land area is given in Table‐2.4.
TABLE – 2.4
LAND BREAK‐UP OF THE PLANT
AREA
(SQ. MT.)
SR.
NO.
LAND USE
EXISTING TOTAL AFTER
PROPOSED EXPANSION
1 Office Building 46.37 66.37
2 Research & Development 29.88 87.88
3 Quality control lab 21.72 51.72
4 Kilo Lab 142.98 142.98
5 Production plant building ‐ 1040.0
6 Utilities building ‐ 448.0
7 Effuent Treatment plant 23.37 223.37
8 Green Belt 258.75 2789.75
9 Storage Godown 60.98 320.98
10 Road, Parking & open sky 432.0 2282.0
11 Solvent storage 25.0 225.0
12 Fuel storage ‐ 62.0
13 Toilets, Security, canteen, clock room, Rest room
39.9 128.9
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14 Storage water 4.0 24.0
15 Storage (Hazadous Waste) 1.72 63.72
16 Storage (Hazardous chemicals) ‐ 130.0
17 Storage (Others) 32.83 85.83
18 Borewell 0.5 1.5
19 Sockpit 5.0 15.0
Total 1,125 8,189
2.5.2 TRANSPORTATION FACILITIES
Transportation of all the raw material and products are primarily by road only and will remain
same after proposed expansion.
2.5.3 WATER AND WASTEWATER
In existing scenario, the total water requirement at M/s. Allchem Laboratories is 1550 Liter/day
which is met through ground water supply. Water consumption is primarily for processing,
washing, gardening and domestic purposes. Total waste water generation is 550 Liter/day.
After proposed expansion, water requirement and waste water generation will increase up to
52,950 Liter/day & 24,950 Liter/day respectively. Additional water requirement shall also meet
through ground water supply and M/s. Allchem Laboratories has applied for grant of permission
for abstraction of ground water to Central Ground Water Authoriy, New Delhi. Details of water
consumption and wastewater generation are given in Table‐2.5 and Water Balance Diagram is
shown in Figure‐2.1.
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TABLE‐2.5
WATER CONSUMPTION & WASTE WATER GENERATION (EXISTING & PROPOSED SCENARIO)
Existing scenario
(Liters/day)
Total after Proposed Expansion
(Liters/day)
Sr.
No.
Section
Water
consumption
Waste water
generation
Water
consumption
Waste water
generation
1 Process 20 20** 3,420 3,420
2 Boiler ‐ ‐ 7,500 1,500
3 Cooling
Tower
‐ ‐ 3,500 1,500
4 RO Plant ‐ ‐ 14,000 5,000
5 Washing
(Floor)
30 30** 8,030 8,030
6 Domestic 500 500* 5,500 5,500*
7 Gardening 1,000 ‐ 11,000 ‐
Total 1,550 550 52,950 24,950
* In existing scenario, domestic wastewater is disposed in Septic Tank/Sock Pit and after proposed expansion; additional domestic waste water quantity will also be disposed in manner as existing scenario. ** In existing scenario, waste water from process and washing is treated in existing ETP and final treated effluent is reused for gardening purpose.
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 56
FIGURE‐2.1
WATER BALANCE DIAGRAM (EXISTING)
Domestic 500 Liter/day
Proecess20 Liter/day
Washing (Floor)30 Liter/day
Gardening1000 Liter/day
Water Consumption 1,550 Liter/day
Domestic W/W 500 Liter/day
Wastewater (W/W)50 Liter/day
ProecessW/W 20 Liter/day
Washing (Floor)W/W 30 Liter/day
ETP
Septic Tank/ Sock PIt
Reused for Gardening Purpose
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FIGURE‐2.1 (CONTD.)
WATER BALANCE DIAGRAM (TOTAL AFTER PROPOSED EXPANSION)
Process W/W 3,420 Liter/day
Domestic 5,500 Liter/day
Boiler 7,500 Liter/day
Washing (Floor)8,030 Liter/day
Gardening11,000 Liter/day
Water Consumption52,950 Liter/day
Domestic W/W 5,500 Liter/day
Cooling3,500 Liter/day
Wastewater19,450 Liter/day
Boiler W/W 1,500 Liter/day
Washing (Floor)W/W 8,030 Liter/day
CoolingW/W 1,500 Liter/day
Proposed ETP
Septic Tank/ Sock PIt
Process 3,420 Liter/day
Send to CETP/Reuse
RO Plant14,000 Liter/day
RO PlantW/W 5,000 Liter/day
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 58
2.5.3.1 TREATMENT PROCESS
M/s. Allchem Laboratories has an Effluent treatment plant. The details of Existing ETP are as
follows.
2.5.3.1.1 EXISTING ETP PROCESS DESCRIPTION
Primary Treatment Tank (Collection cum Neutralization Tank):
Tank acts collection cum Neutralization Tank. Effluent generated is collected and neutralized in
this tank. Lime solution or Hydrochloric Acid is added as per requirement in the collection cum
neutralization tank for adjust neutral pH. The equalization & mixing carried out by help of
pressurized air. Neutralized effluent being pumped into settling tanks at the high levels.
Settling Tank:
This tank acts as a buffer between the primary treatment tank and the overflow tank into which the
settled water flows by gravity.
Effluent after neutralization flow in settling tanks (2 nos.) & then the poly electrolyte powder
added as flocculating agent in the effluent. Flocculation is completed with help of agitation.
Then the effluent is retained for the certain period in a relatively quiescent state. Thus,
Chemical flocs having higher specific gravity than the liquid tend to settle to the tank bottom.
The supernant is transfered to gravity filter. The settled sludge at the bottom is transfer to the
designated sludge drying beds.
Overflow Tank:
Overflow tank has two compartments to allow for settling of particulate matter which might have
escaped from the settling tank.
Charcoal/Sand Filter:
Charcoal/Sand Filter tanks retain any suspended solid and trace of organic material, if present.
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2 ‐ 59
Holding Tank:
This tank, situated next to the charcoal/sand filter tank at the ground level, collects the water comes
out of the charcoal filter. The effluent collected in holding tank then reused for gardening purposes.
List of ETP units are given in Table‐2.6. & Flow diagram is given in Figure‐2.2.
TABLE‐2.6
LIST OF ETP UNITS (EXISTING)
Sr. No. Name of unit No. of
unit
Dimension in
(meter)
Volume
Capacity (m3)
1. Primary Treatment Tank (Collection
cum Neutralization Tank)
1 2.6 x 2.9 x 1.46 11
2. Settling Tank 2 1.2 x 1.2 x 1.2 1.72
3. Overflow Tank 2 1.1 x 1.1 x 0.5 0.6
4. Charcoal/Sand Filter 1 + 1 0.92 x 0.92 x 0.5 0.42 (each)
5. Holding Tank 1 1.4 x 1.4 x 1.13 2.2
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FIGURE‐2.2
FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT (EXISTING)
Primary Treatment Tank
(Collection cum Neutralization Tank)
Raw Effluent
Settling Tank
(2 Nos.)
Overflow Tank
(2 Nos.)
Sand Filter
Charcoal Filter
Holding Tank
Treated Effluent is reused for Gardening
D:\EIA\ALLCHEM LABORATORIES\PH\CD\EIA‐WORD\EIA‐I.DOC 2‐ 61
2.5.3.1.2 PROPOSED ETP PROCESS DESCRIPTION
After proposed expansion, effluent load will be increased.
Wastewater from the proposed project will be generated from following strems
• Process
• Washing
• Cooling tower blow down
• Boiler blow down
• Softening plant regeneration and RO plant reject water
• Scrub liquid
are separated in the systematic ways and treated in following ways
Option ‐1: To treat the additional effluent load, company is proposing a new ETP consists of primary treatment facility. Details
of the proposed ETP plant with unit dimensions are given below.
Raw effluent from all the plants will be collected in oil Greece sperator where oil or hyrdrocarbon shall be
separated and than collect the effluent in Collection tank. After collection of effluent, transfer in the neutralization
tank in which one No. of agitator shall be provided in CET to keep all suspended solids in suspension and to provide
proper mixing.
The effluent is then pumped to Neutralization Tank (NT), where the continuous addition and stirring of lime slurry
from Lime Dosing Tank (LDT) is done to maintain the pH of wastewater. Then after, neutralized wastewater shall
go to Flash Mixer (FM) by gravity. Alum/ Polyelectrolite shall be dosed from Alum Dosing Tank (ADT)/
Polyelectrolite Dosing Tank (PEDT) respectively into FM to carry out coagulation by using a Flash Mixer mechanism
(FMM).
Then after, neutralized wastewater shall go to primary Settling Tank (PST) and secondary settling tank (SST) by pipe
where the suspended solids are allowed to settle down. decanted effluent and from sluge drying bed i.e. filltrate
passes to Intermediate Sump (IS), where aeration or hydrogen peroxide trement is given.
Then after, the wastewater shall be pumped to Pressure Sand Filter (PSF) and Activated Carbon Filter (ACF) before
final discharge to remove any left out impurities such as Color, SS, COD, etc.
Treated effluent shall be collected in Treated Effluent Sump (TES) and will be sent to CETP of M/s. EICL for further
treatment and final disposal. If, required Hydrogen Peroxide or areation dosing can be carried out in Treated
Effluent Sump to meet the discharge or reuse norms.
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Primary sludge settled in Primary Settling Tank shall be dewatered in Sludge Drying Beds (SDB). Filtrate Water shall
be collected in CET.
List of ETP units are given in Table‐2.7. & Flow diagram is given in Figure‐2.3.
TABLE‐2.7
LIST OF ETP UNITS (PROPOSED) (CAPACITY ~ 3 LAC LITRES)
Sr. No. Name of Units Size (m x m x m) Capacity
(Liters)
1 Oil and Grease Seperator 2.0 x 2.0 x 1.2 4800.00
2 Effluent Collection Sump 4.0 x 4.0 x 2.0 32000.00
3 Neutralization Tank 4.0 x 4.0 x 2.0 32000.00
4 Primary Settler Tank 3.46 x 3.46 x 2.5 29929.00
5 Secondary Settler Tank 3.46 x 3.46 x 2.5 29929.00
6 Aeration Tank 4.0 x 4.23 x 2.0 33840.00
7 Pressure Sand Filter 2.0 x 2.0 x 1.5 6000.00
8 Activated Carbon Filter 2.0 x 2.0 x 1.5 6000.00
9 Sludge Drying Bed 15.85 x 2.0 x 1.5 47550.00
10 Treated Effluent Sump 7.0 x 4.0 x 2.5 70000.00
Option‐2: Concentrated process effluent liquid is taken to own effluent treatment plant comprising of
primary treatment units where wastewater is treated by physico chemical treatment and than
it will be sent to EICL, Umraya, and Vadodara for the treatment and final disposal.
Rest of the Industrial effluent generation is taken to own effluent treatment plant comprising of
primary treatment units where wastewater is treated by physico chemical treatment. The
treated waste water is further passed through Multiple Effect Evaporator followed by Thin Film
Dryer. After evaporation and condensation, outlet water confirming to the GPCB norms is
reused as boiler feed water, in process or disposal on land will be utilized for gardening purpose
within premises after blending it with fresh water (which is used in gardening). “
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FIGURE‐2.3
FLOW DIAGRAM OF EFFLUENT TREATMENT PLANT (PROPOSED)
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2.5.3.2 REVERSE OSMOSIS (RO) SYSTEM
M/s. Allchem Laboratories will be installed Reverse Osmosis (RO) System. The details are as
follows.
Water Treatment scheme is designed to produce product water at the flow rate of 1000 LPH
based on Reverse Osmosis Technology.
Unit Process Description
Sr. No. Description Specification
1 Raw Water Pump To feed raw water to the system
2 Pressure sand filter Removal of suspended impurities
3 Activated Carbon filter Removal of odor & color
4 Micron filtration Silt density index (SDI) reduction
5 Anti‐scalant dosing Scale inhibition; by lowering the LSI
6 Reverse osmosis Primary desalination (TDS reduction)
Treated Water Quality
Sr. No. Description Specification
1 pH 6 + Mildly acidic
2 RO plant salt rejection > 90% after 3 days
3 Organics & bacteria removal 99%
4 TDS less than 100
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DETAILED SPECIFICATIONS:
Process flow diagram
Operating Specifications
Sr. No. Description Specification
1 Product water flow rate 1000 LPH
2 Overall system recovery 60%
3 System salt rejection > 90% nominal (90%min)
4 Feed water flow rate 1600 LPH
5 Reject water flow rate 600 LPH
6 Design temperature 30 oC
Raw Water Pump : 1 no.
Pressure sand filter : 1 no.
Activated Carbon filter : 1 no.
Micron filtration : 1 no.
Anti‐scalant dosing System : 1 no.
RO Feed Pump : 1 no.
RO Membrane Assembly : 1 no.
Product Water storage (by client)
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Equipment Offered
Sr. No. Description Specification
1 Raw Water Pump 1 No.
2 Pressure sand filter 1 No.
3 Activated Carbon filter 1 No.
4 Micron filtration 1 No.
5 High Pressure Pump and Motor 1 No.
6 RO Membranes 1 No.
7 RO Membranes Housing 1 No.
8 RO Instrumentation & controls 1 No.
9 RO Control panel, R.O. Frame 1 No.
Operating Specifications
Sr. No. Description Specification
1 Raw Water Pump 1 No.
2 HP 1
3 Make Kirloskar/ Beacon/ Equivalent
4 Type CI monoblock centrifugal with gland packing
5 Delivery 2.8 m3/hr. at 25 meter head
6 Pipe line 25 mm Rigid PVC
Pressure Sand FIlter
Sr. No. Description Specification
1 No. of units 1 No.
2 Capacity 2.0 m3/hr. max
3 Dimensions 300 mm Dia ¢ 1200 mm Height
4 MOC FRP
5 Inlet TSS 30 ppm max
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6 Outlet TSS 3 max
7 Design pressure 3 bar
8 Main pipeline size 40 NB
9 Pressure Gauge 1 No.
10 Valves 40 NB multiport
Activated Carbon FIlter
Sr. No. Description Specification
1 No. of units 1 No.
2 Capacity 2.0 m3/hr. max
3 Dimensions 300 mm Dia ¢ 1200 mm Height
4 MOC FRP
5 Design pressure 3 bar
6 Main pipeline size 25 NB
7 Pressure Gauge 1 No.
8 Valves 25 NB multiport
Micron FIlter
Sr. No. Description Specification
1 No. of units 1 No.
2 Capacity 2.0 m3/hr. max
3 Delta across clean filter 0.4 bar
4 End of filtration delta 0.8 bar
5 Design pressure 3 bar
6 Centrifuge 1 Set
7 Housing 1 No.
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Chemical Dosing System: 1 No. (Antiscalent)
Sr. No. Description Specification
1 No. of units 1 No.
2 Solution holding tank 1 no; 100 ltrs;
3 Metering Pump 1 no; 3 LPH @ 3.5 bar; PP wetted parts
220 V; 50 Hz; e dose/equi
4 Piping 3/8” Flexible PVC tuning;
5 Valves 1 no ea; PP fool valve & NRV provided
High Pressure Pump with motor
Sr. No. Description Specification
1 Quantity 1 No.
2 Delivery 2000 lph @ 14 bar
3 MOC SS
4 Make Bell/ Nan fang/ Equiv.
5 Motor rating 3 HP, 440 Volts, 50 Hz, 1440 RPM
6 Type Multistage
RO Membranes
Sr. No. Description Specification
1 No 4 Nos.
2 Elements Type TFC Spiral wound
3 Membrane Polymer Composite polyamide
4 Model Hydronautics/ Koch membrane –
USA/Equiv.
5 Membrane array (1 ¢ 2) (1 ¢ 2)
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RO Membrane Housing
Sr. No. Description Specification
1 Qty. 2 no.
2 MOC FRP
3 Pressure Rating 17 Kg
4 Membrane per housing 2 no.
RO Instrumentation & Controls
Sr. No. Description Specification
1 High pre. shut off switch 1 no.
2 Liquid filled Pr. Gauges 2 nos; SS; 0‐20 bar; Hg/Equiv.
3 Tubular Rota meters 2 nos; acrylite; Aster/ Equiv.
4 Conductivity indicator 1 no.; Aster/ Equiv.
5 Control Valves Flow – 1 no; SS; Globe; 25 NB
6 Piping High Pressure – CPCV
High pressure tubing – CPVC
Pressure tubing ‐ CPCV
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FIGURE‐2.4
FLOW DIAGRAM OF RO PLANT
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2.5.4 DETAILS OF UTILITIES
Various utilities are required for proper functioning of manufacturing plants. These utilities include boiler, thermic fluid heater,
cooling tower, brine plant, chilling Plant, RO water plant, air compressor, DM water plant, DG set, etc. Details of utilities services are
in Table 2.8.
TABLE ‐ 2.8
THE DETAILS OF UTILITIES
SR.
NO.
NAME OF EUIPMENT TYPE MAKE CAPACITY LOCATION
1 Boiler IBR Energy Process Equipment 800 kg/hour Boiler house, Utilities building
2 Thermic fluid heater IBR Energy Process Equipment 2 lac KL/hour Boiler house, Utilities building
3 Cooling tower Natural Draft Matangi 80 TR Above utilities building
4 Cooling tower Natural Draft Matangi 80 TR Above utilities building
5 Cooling tower Natural Draft Matangi 300 TR Production building
6 Chilling plant R‐22 gas Refcon 40 TR at ‐5 deg C Utilities building
7 Brine plant R‐22 gas Refcon 20 TR ‐20 deg C Utilities building
8 Air compressor Reciprocating Khosla 50 m3/hour Utilities building
9 RO water Ion exchange BT associates 1000 litr/hour Utilities building
10 DM water Softener BT associate 500 lit/hour Utilities building
11 DG set Diesel Greaves Make 100 KVA Utilities building
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2.5.5 ELECTRICITY REQUIREMENT
The power requirement at M/s. Allchem Laboratories is meeting through 22 KW connecting
load of GEB. After proposed expansion, total power requirement will be increased up to 100
KW which will also be fulfilled by GEB and D.G. set of 100 KVA will be installed for used in
emergency only.
2.6 POLLUTION POTENTIAL AND ITS CONTROL MEASURE
2.6.1 AIR POLLUTION AND CONTROL SYSTEM
At M/s. Allchem Laboratories, there are no stacks/vents within existing plant so no air pollution
is involved in production as well as utilities. After proposed expansion, company will be
installed one Steam Boiler, one Thermic Fluid Heater, one D.G. set of Capacity 100 KVA for
emergency use only and Process Vents. To control the emission from process vents, adequate
water scrubber, alkali scrubber, water scrubber followed by alkali scrubber will be installed. The
details of stack & vent are given below in Table 2.9.
TABLE ‐ 2.9
THE DETAILS OF SOURCE OF EMISSION & CONTROL MEASURES (PROPOSED SCENARIO)
Sr.
No
Source of
Emission
Type of
Emission
Stack
Height
(meter)
Stack
Diameter
(meter)
Fuel
name
and
Quantity
Pollution Control
Equipment
1 Steam Boiler SPM
SOx
Nox
12 0.225 Biomass
(Agro Waste)
1 MT/day
‐
2 Thermic Fluid
Heater
SPM
SOx
NOx
12 0.225 Biomass
(Agro Waste)
1 MT/day
‐
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3 Process Vent‐I SO2
15
0.3
‐ Alkali scrubber
4 Process Vent‐II HCl
15
0.3 ‐ Water scrubber
followed by Alkali
scrubber
5 Process Vent‐III Ammonia
15
0.3
‐ Two stage Water
scrubber
6 Process Vent‐IV CO2
‐ ‐ ‐ Open vent or
Alkali scrubber
7 Process Vent‐V HBr 15 0.3
‐ Water scrubber
followed by Alkali
scrubber
8 D.G. Set – 100 KV
(Stand by
Arrangement)
SPM
SOx
NOx
7 0.115 Diesel
(15 Liter/hour)
‐
2.6.1.1 BOILER DETAIL
Steam Boiler
Capacity : 800 kg/hour
Type : IBR
Make : Energy Process Equipment
Stack Height : 12 meter
Stack Diameter : 0.225 meter
Fuel name and Quantity : Biomass (Agro Waste) & 1 MT/day
Thermic fluid heater
Capacity : 2 lac KL/hour
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Type : IBR
Make : Energy Process Equipment
Stack Height : 12 meter
Stack Diameter : 0.225 meter
Fuel name and Quantity : Biomass (Agro Waste) & 1 MT/day
2.6.1.2 SCRUBBER SYSTEM
At M/s. Allchem Laboratories, Process Vents will be attached to scrubbing system to reduce the
emission. The design parameters are as follows.
Scrubber System‐I
Pollutant: HCl, HBr
Srubbing Media: Caustic Soln.
Scubber MOC: HDPE
Scrubber Diameter: 300 mm
Scrubber Height: 4 meter
Scrubber System‐II
Pollutant: Ammonia
Srubbing Media: Water
Scubber MOC: HDPE
Scrubber Diameter: 200 mm
Scrubber Height: 2 meter
Scrubber System‐III
Pollutant: SO2
Srubbing Media: Caustic
Scubber MOC: HDPE
Scrubber Diameter: 200 mm
Scrubber Height: 2 meter
The flow diagram of of scrubber stystem are given in Figure‐2.5.
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FIGURE‐2.5
SCRUBBER SYSTEM‐I
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FIGURE‐2.7 (CONTD.)
SCRUBBER SYSTEM‐II
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FIGURE‐2.7 (CONTD.)
SCRUBBER SYSTEM‐III
vent from reactor
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2.6.2 NOISE LEVEL AND CONTROL SYSTEM
The sources of noise pollution at site will be pumps, blowers, D.G. Set (stand by) etc. Extensive
oiling and lubrication and preventive maintenance shall carried out to reduce noise generation
at source to the permissible limit. However, at place where noise levels can exceed the
permissible limit, Earplugs and Earmuffs shall be provided to those working in such area.
2.6.3 HAZARDOUS AND SOILD WASTE GENERATIONS AND DISPOSAL SYSTEM
Six categories of hazardous wastes are generated at M/s. Allchem Laboratoires. Mode of
disposal followed is as per HW (Management, Handling and Transboundary Movement) Third
Amendment Rules, 2010 of Environment Protection Act, 1986.
In existing scenario, hazardous waste generation is ETP sludge and used containers. ETP sludge
is sent to TSDF of NECL, Nandesari for final disposal. Used containers are sold to actual recycler
after decontamination.
After proposed expansion, quantity of ETP sludge and Used containers will be increased and will
be disposed in same manner as existing. Additional hazardous waste generation will be used oil,
distillation residue, spent carbon and spent solvent. Used oil will be sold to Registered Refiner.
Distillation Residue will be sent to NECL, Nandesari for incineration. Spent Carbon will be sent
to TSDF of NECL, Nandesari for final disposal. Spent solvent will be given to end user or sent to
NECL, Nandesari for incineration.
Hazardous waste generation quantity, physical characteristics and mode of disposal are given in
Table‐2.10.
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TABLE‐2.10
HAZARDOUS & SOILD WASTE GENERATION QUANTITY, PHYSICAL CHARACTERISTICS AND MODE OF DISPOSAL
Quantity Sr. No. Name
of
Waste
Category Waste
generating
process / step
Physical
characteristicsExisting
Total after
Proposed
Expansion
Mode of
disposal
1 Used Oil 5.1 Plant Maintenance Liquid ‐ 30 Liter/Month Collection, Storage,
Transportation, Disposal by
Selling to Registered Refiner
2 Distillation Residue
20.3 Process Semi Liquid ‐ 8 MT/Month Collection, Storage,
Transportation, Disposal at
NECL for incineration
3 Spent Carbon 35.3 Process Solid ‐ 0.5 MT/Month Collection, Storage,
Transportation, Disposal at
TSDF of NECL, Nandesari
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4 Spent Solvent 28.5 Process Liquid ‐ 8 MT/Month Given to end user /Incineration at
CHWI
5 Used Container
33.3 Process Solid 144 No./Month
400 No./Month
Collection, Storage,
decontamination and send to
actual recycler
6 ETP Sludge 34.3 ETP Semi‐solid 0.03 MT/Month
15 MT/Month
Collection, Storage, Transportation,
Disposal at TSDF of NECL,
Nandesari
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2.6.4 DETAILS OF GREENBELT
The main objective of the green belt is to provide a barrier between the plant and surroundings
areas. M/s. Allchem Laboratories has developed green belt within factory premises. In existing
scenario, about 1,125 sq. meter of the total land area is available at site; out of this area about
258.75 sq. meter (23 %) area is covered as greenbelt and other forms of greenery. After
proposed expansion, total about 8,189 sq. meter of land area shall be available; out of this area
total about 2,789 sq. meter (34.05 %) area will be developed as greenbelt and other forms of
greenery.