SESHA SAI CHEMICALS PVT. LTD. - Welcome to Environmentenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0...Sesha Sai Chemicals Pvt. Ltd., Form I Page 5 2. Use of Natural resources

SESHA SAI CHEMICALS PVT. LTD. SY.NO. 159/1 (PART), KANDIVALASA VILLAGE,

PUSAPATIREGA MANDAL, VIZIANAGARAM DISTRICT, ANDHRA PRADESH

FORM I

Project No. 1214‐21‐01December 2014

Sesha Sai Chemicals Pvt. Ltd., Unit III Plot No. 51, IDA Cherlapaly, HCl‐PO, Hyderabad – 500 051. Phone: +91 9885321459 E‐mail ID: [email protected]

STUDIES AND DOCUMENTATION BY TEAM Labs and Consultants B‐115‐117 & 509, Annapurna Block, Aditya Enclave, Ameerpet, Hyderabad‐500 038. Phone: 040‐23748 555/23748616, Telefax: 040‐23748666

SUBMITTED TO MINISTRY OF ENVIRONMENT AND FORESTS,

GOVERNMENT OF INDIA INDIRA PARYAVARAN BHAWAN, JOR BAGH ROAD, NEW DELHI

Sesha Sai Chemicals Pvt. Ltd.,

Form I Page 1

APPENDIX – I (See Paragraph – 6)

FORM I I) Basic Information S.No. Item Details 1 Name of the Project/s Sesha Sai Chemicals Pvt. Ltd., 2 S. No in the Schedule 5 f – A category 3 Proposed capacity/area/length/tonnage to

be handled/command area/lease area/number of wells to be drilled

API’s (Synthetic Organic Chemicals). Capacity: 5400 Kg/day (Phase I: 4000Kg/day & Phase II: 1400Kg/day) Propose to manufacture 4 products in Phase I (Regular products) and 4 Products in Phase II respectively out of a total 30 products on campaign basis.

4 New/Expansion/Modernization New5 Existing Capacity/Area etc. Not Applicable6 Category of Project i.e. 'A' or 'B' “A” 7 Does it attract the general condition? If yes,

please specify No

8 Does it attract the Specific condition? If yes, please specify.

No

9 Location Plot/Survey/Khasra No. Sy. No. 159/1 (Part) Village Kandivalasa Village Tehsil Pusapatirega Mandal District Vizianagaram District State Andhra Pradesh 10 Nearest railway station/airport along with

distance in kms. Railway Station: Vizianagaram– 17 Km Airport : Visakhapatnam – 56 Km

11 Nearest Town, City, District Headquarters along with distance in kms.

Vizianagaram ‐ 17 Km

12 Village Panchayats, Zilla Parishad, Municipal Corporation, Local body (complete postal address with telephone nos. to be given)

Attivaram Village

13 Name of the Applicant B. Lakshmana Rao 14 Registered Address Sesha Sai Chemicals(p)Ltd ,Unit III

Plot No:51, IDA Cheeralapally, HCl‐PO, Hyderabad, Telangana

15 Address for Correspondence: Name B. Lakshmana Rao Designation(Owner/Partner/CEO) Managing Director


Form I Page 2

Address Sesha Sai Chemicals(p)Ltd ,Unit III Plot No:51, IDA Cheeralapally, HCl‐PO, Hyderabad, Telangana

Pin Code 500 051 E‐mail [email protected]

Telephone Number 040‐27260934; +91‐9885321459 Fax No. 040‐23748666 16 Details of alternative Sites examined, if any.

Location of these sites should be shown on a topo sheet.

‐NA‐

17 Interlinked Projects ‐NA‐ 18 Whether separate application of interlinked

project has been submitted? No

19 If yes, date of submission 20 If no, reason 21 Whether the proposal involves

approval/clearance under: if yes, details of the same and their status to be given. (a) The Forest (Conservation) Act, 1980? (b) The Wildlife (Protection) Act, 1972? (c) The C.R.Z Notification, 1991?

‐NA‐

22 Whether there is any Government Order/Policy relevant/relating to the site?

No

23 Forest land involved (hectares) No 24 Whether there is any location pending

against the project and /or land in which the project is propose to be set up? (a) Name of the Court (b) Case No (c) Orders/directions of the Court, if any and its relevance with the proposed project.

No


Form I Page 3

(II) Activity

1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.) S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate quantities

/rates, wherever possible) with source of information data

1.1 Permanent or temporary change in land use, land cover or topography including increase in intensity of land use (with respect to local land use plan)

NO The proposal is for a green field project. The land area is 14.8acres. The site is plain industrial plot and does not involve much of leveling/excavation.

1.2 Clearance of existing land, vegetation and buildings?

NO The site is plain and is not used for any agricultural activity, clearance mainly of shrubs and bushes only.

1.3 Creation of new land uses? NO 1.4 Pre‐construction investigations e.g.

bore houses, soil testing? YES Soil test done and soil load bearing capacity

established. 1.5 Construction works?

NO Construction activity involves plant

construction, erection only. 1.6 Demolition works? NO

1.7 Temporary sites used for construction works or housing of construction workers?

NO Construction labor from local villages shall be employed.

1.8 Above ground buildings, structures orearthworks including linear structures, cut and fill or excavations

YES Office buildings, Production blocks, Storage facilities for raw material and final products shall be constructed. No major cut and fill or excavation is anticipated.

1.9 Underground works including mining or tunneling?

NO

1.10 Reclamation works? NO 1.11 Dredging? NO 1.12 Offshore structures? NO 1.13 Production and manufacturing

processes? YES Enclosed in Annexure – I

1.14 Facilities for storage of goods or materials?

NO Raw materials and solvents shall be stored with safety precautions.

1.15 Facilities for treatment or disposal of solid waste or liquid effluents?

YES Solid waste shall be disposed to end users/recyclers or sent to incineration. Effluent generated from the plant are treated and reused. Details presented in Annexure II

1.16 Facilities for long term housing of operational workers?

NO Local people shall be employed.


Form I Page 4

1.17 New road, rail or sea traffic during construction or operation?

YES Construction materials shall be transported to the site. The traffic density of the existing connecting road is negligible.

1.18 New road, rail, air waterborne or other transport infrastructure including new or altered routes and stations, ports, airports etc?

NO

1.19 Closure or diversion of existing transport routes or infrastructure leading to changes in traffic movements?

NO

1.20 New or diverted transmission lines or pipelines?

NO

1.21 Impoundment, damming, culverting, realignment or other changes to the hydrology of watercourses or aquifers?

NO

1.22 Stream crossings? NO 1.23 Abstraction or transfers of water

form ground or surface waters? YES Total water required after Phase II shall be

203.22 KLD out of which 125.72 KLD shall be drawn from bore well and the balance shall be recycled water. (Water Balance Enclosed in Annexure III)

1.24 Changes in water bodies or the land surface affecting drainage or run‐off?

NO

1.25 Transport of personnel or materials for construction, operation or decommissioning?

YES The construction material shall be drawn from local sources within 10 – 15 km. There is no transport of personnel, as the construction workers shall be drawn from local villages.

1.26 Long‐term dismantling or decommissioning or restoration works?

NO

1.27 Ongoing activity during decommissioning which could have an impact on the environment?

NO

1.28 Influx of people to an area in either temporarily or permanently?

YES The proposed project shall increase the employment potential and hence may lead to migration to surrounding villages.

1.29 Introduction of alien species? NO 1.30 Loss of native species or genetic

diversity? NO There are no major losses of tree/shrub

species. 1.31 Any other actions? NO


Form I Page 5

2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non‐renewable or in short supply): S.No. Information/checklist confirmation Yes/No Details thereof (with approximate quantities

/rates, wherever possible) with source of information data

2.1 Land especially undeveloped or agricultural land (ha)

YES 14.8acres. Located at Sy. No. 159/1 (Part), Kandivalasa Village, Pusapatirega Mandal, Vizianagaram District, Andhra Pradesh.

2.2 Water (expected source & competing users) unit: KLD

YES Total water required after Phase II shall be 203.22 KLD out of which 125.72 KLD shall be drawn from bore well and the balance shall be recycled water. (Water Balance Enclosed in Annexure III)

2.3 Minerals (MT) NA 2.4 Construction material – stone,

aggregates, sand / soil (expected source – MT)

YES Shall be sourced from the local villages.

2.5 Forests and timber (source – MT) NO 2.6 Energy including electricity and fuels

(source, competing users) Unit: fuel (MT), energy (MW)

YES The required energy shall be drawn from APTRANSCO. The power shall be drawn from backup DG sets of 125KVA in Phase I & 250KVA in Phase II shall be provided to cater to energy requirement during power shut downs period. The other energy source is Coal fired boilers of 2TPH and 4TPH in Phase I and II respectively to meet the steam requirement. The required quantity of fuel (coal) after Phase II shall be 26TPD and diesel for Standby DG sets shall be 206Lts/hr.

2.7 Any other natural resources (use appropriate standard units)

NA


Form I Page 6

3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health. S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate

quantities/rates, wherever possible) with source of information data

3.1 Use of substances or materials, which are hazardous (as per MSIHC rules) to human health or the environment (flora, fauna, and water supplies)

YES Solvents shall be used as reaction media. MSIHC rules shall be followed during storage, transportation and handling of raw materials and hazardous chemicals.

3.2 Changes in occurrence of disease or affect disease vectors (e.g. insect or water borne diseases).

NO

3.3 Affect the welfare of people e.g. by changing living conditions?

YES Shall increase the employment potential for locals and affect the living conditions for betterment.

3.4 Vulnerable groups of people who could be affected by the project e.g. hospital patients, children, the elderly etc.,

NO No sensitive receptors are present in the immediate vicinity of the site. The project shall not have any significant impact on vulnerable groups of people.

3.5 Any other causes NO

4. Production of solid wastes during construction or operation or decommissioning (MT/month) S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate


4.1 Spoil, overburden or mine wastes NO 4.2 Municipal waste (domestic and or

commercial wastes) NO Wastes from canteen, other commercial

wastes like paper, empty containers etc. The canteen wastes and commercial wastes shall be in the range of 15 kg/day

4.3 Hazardous wastes (as per Hazardous Waste Management Rules)

YES The quantity of hazardous wastes generated during construction contains waste oils and batteries from DG set.

The quantity of hazardous waste generated during operation contain salts from evaporators, stripper distillate, process residue, and solvent residues, ETP sludge and filtration media etc. enclosed in Annexure – IV


Form I Page 7

4.4 Other industrial process wastes YES Enclosed at Annexure IV 4.5 Surplus product NO 4.6 Sewage sludge or other sludge from

effluent treatment YES Sludge from Effluent treatment plant and

Salts from MEE & ATFD shall be sent to TSDF.

4.7 Construction or demolition wastes NO

4.8 Redundant machinery or equipment NO 4.9 Contaminated soils or other materials NO 4.10 Agricultural wastes NO

4.11 Other solid wastes NO Enclosed at Annexure IV

5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr) S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate


5.1 Emissions from combustion of fossil fuels from stationary or mobile sources

YES Coal Shall be used as fuel. Quantity of fuel and emissions details are enclosed in Annexure V

5.2 Emissions from production processes YES Enclosed in Annexure ‐ VI 5.3 Emissions from materials handling

including storage or transport NO Material transfer takes place in closed

pipeline systems. 5.4 Emissions from construction activities

including plant and equipment YES Dust may rise during transport of material and

construction activity. The dust emissions shall be mitigated by water spraying on the roads within the premises.

5.5 Dust or odors from handling of materials including construction materials, sewage and waste

NO

5.6 Emissions from incineration of waste NO 5.7 Emissions from burning of waste in

open air (e.g. slash materials, construction debris)

NO

5.8 Emissions from any other sources NO


Form I Page 8

6. Generation of Noise and Vibration, and Emissions of Light and Heat: S.No. Information/Checklist

confirmation Yes/No Details thereof (with approximate

quantities/rates, wherever possible) with source of information data with source of information data

6.1 From operation of equipment e.g. engines, ventilation plant, crushers

YES Material transport and construction equipment shall be source of noise, while transfer pumps, vacuum systems, DG sets are the sources of noise during operation.

6.2 From industrial or similar processes

YES From DG sets, and controlled by providing Acoustic Enclosures.

6.3 From construction or demolition YES Noise during construction shall be due to construction equipment and emergency DG sets.

6.4 From blasting or piling NO

6.5 From construction or operational traffic

NO The increased traffic shall not have any significant impact.

6.6 From lighting or cooling systems NO

6.7 From any other sources NO

7.Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal waters or the sea: S.No. Information/Checklist

confirmation Yes/No Details thereof (with approximate


7.1 From handling, storage, use or spillage of hazardous materials

NO All the hazardous materials will be stored in Tanks/MS drums, in a covered shed and no contamination of soil is expected

7.2 From discharge of sewage or other effluents to water or the land (expected mode and place of discharge)

NO All the wastes from domestic operations are sent to septic tank followed by soak pit.

7.3 By deposition of pollutants emitted to air into the land or into water

NO Air Pollutants generated are let out into atmosphere after meeting the prescribed standards.

7.4 From any other sources NO 7.5 Is there a risk of long term build

up of pollutants in environment from these sources?

NO


Form I Page 9

8.Risk of accidents during construction or operation of the Project, which could affect human health or the environment S.No. Information/Checklist confirmation Yes/No Details thereof (with approximate


8.1 From explosions, spillages, fires etc from storage, handling, use or production of hazardous substances

YES All Inbuilt Safety precautions will be adopted and there will not be any damage to environment or human health

8.2 From any other causes NA 8.3 Could the project be affected by natural

disasters causing environmental damage (e.g? Floods, earthquakes, landslides, cloudburst etc)?

NO

9.Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality S. No. Information/Checklist confirmation Yes/No Details thereof (with approximate


9.1 Lead to development of supporting. facilities, ancillary development or development stimulated by the project which could have impact on the environment e.g.: • Supporting infrastructure (roads, power supply, waste or waste water treatment, etc.)• housing development • extractive industries • supply industries • other

YES The project shall enhance the socio economic status of the area by increasing the demand for housing, improving the employment. There are no major support industries required for this plant.

9.2 Lead to after‐use of the site, which could haven impact on the environment

NO

9.3 Set a precedent for later developments NO 9.4 Have cumulative effects due to proximity to

other existing or planned projects with similar effects

NO The baseline environmental status of the surrounding areas is within the prescribed limits as observed from the Secondary data.


Form I Page 10

(III) Environmental Sensitivity S.No. Areas Name/

IdentityAerial distance (within 15 km.) Proposed project location boundary

1 Areas protected under international conventions, national or local legislation for their ecological, landscape, cultural or other related value

NA

2 Areas which are important or sensitive for ecological reasons ‐ Wetlands, watercourses or other water bodies, coastal zone, biospheres, mountains, forests

YES Kumili RF – 3.3 Km – Northwest Konada RF – 9.6 Km – Northwest Kandivalasa River – 3.2Km – East Bay of Bengal – 9 Km ‐ Southeast

3 Areas used by protected, important or sensitive species of flora or fauna for breeding, nesting, foraging, resting, over wintering, migration

NA

4 Inland, coastal, marine or underground waters

NO

5 State, National boundaries NO 6 Routes or facilities used by the public for

access to recreation or other tourist, pilgrim areas

NO

7 Defense installations NO 8 Densely populated or built‐up area YES Kandivalasa is at a distance of 1.89

Km in southeast with population of 1330.

9 Areas occupied by sensitive man‐made land uses (hospitals, schools, places of worship, community facilities)

NA

10 Areas containing important, high quality or scarce resources (ground water resources, surface resources, forestry, agriculture, fisheries, tourism, minerals)

NO

11 Areas already subjected to pollution or environmental damage. (those where existing legal environmental standards are exceeded)

NO

12 Areas susceptible to natural hazard which could cause the project to present environmental problems (earthquakes, subsidence, landslides, erosion, flooding or extreme or adverse climatic conditions)

NO


Form I Page 11

(IV) Proposed Terms of Reference for EIA studies Scope of Work of EIA “...The EIA shall cover the following: Description of the proposed project: The first task:” Description of the proposed project” forms a vital component of the Environmental Impact Assessment (EIA) as it provides the basis for evaluating the likely causes of Environmental Impacts.

Existing Environment and Baseline Conditions: The baseline assessment will be carried out to identify potentially sensitive and critical areas that may be affected by the project in an area of 10 km surrounding the project location. The critical and sensitive targets shall be plotted on land use map of project impact area. The existing environment and baseline conditions should be established from:‐ Analysis of existing information published and secondary data. ‐Consultation with relevant statutory authorities, and Field visits for supplementation of missing gaps.

The key subject areas which the EIA shall address include Ecology and Nature conservation, Air quality, surface and water quality in project impact area, soil quality, cultural heritage, landscape, land use, noise quality, etc. Natural habitats like national parks, wildlife reserves, sanctuaries, sacred grove, protected areas, forests, wetlands, major rivers and waterways if any, shall also be identified and marked.

Assessment of Environmental Impacts: Based upon the results from the review of existing information, field visits, site data collection and consultation, for each component of environment (physical, biological and socio economic) the positive, negative, direct and indirect, temporary and permanent impacts will be evaluated along with an indication of the degree of impact, i.e., whether the impact is significant, moderate, minor or negligible. The degree of impact shall also be quantified by using state of the art air quality impact prediction models based on ISCST3 algorithms.

Environment Management Plan And Mitigation Plan: For each significant negative impact identified, specialist shall work closely with the engineering team/technical consultants to suggest practicable measures to avoid or mitigate the impact. The mitigation of environmental impacts will be by three mechanisms. =>Introduction of mitigation features through the engineering practices. =>Implementation of environmental controls during construction and operation. =>Legislative control involving compliance with Indian environmental laws. The Environmental management plan shall include an estimate of capital and recurring costs of mitigation measures and will identify the institutional framework for implementation.

Monitoring Plan: Having identified the significant environmental impact that is likely to arise as a result of the project, the project team shall specify what monitoring is required during the various phases of the project cycle. The monitoring plan will identify parameters and frequency of monitoring and responsible organization.


Form I Page 12

I hereby give the undertaking that data and information given in the application and enclosures are true to the best of my knowledge and belief and I am aware that if any part of the data and information submitted is found to be false or misleading at any stage, the project will be rejected and clearance given, if any to the project will be revoked at our risk and cost.

Date:

Place:

Signature of the applicant With Name and Full Address

(Project Proponent/Authorized Signatory)

B. Lakshmana Rao Managing Director

Sesha Sai Chemicals Pvt. Ltd., Unit III Plot No. 51, IDA Cherlapally, HCl‐PO,

Hyderabad – 500 051 Mail Id: [email protected],

Mobile No. +91 9885321459



ANNEXURES

SUBMITTED TO MINISTRY OF ENVIRONMENT AND FORESTS,

GOVERNMENT OF INDIA INDIRA PARYAVARAN BHAWAN, JOR BAGH ROAD, NEW DELHI

Sesha Sai Chemicals Pvt. Ltd., Form I Annexures

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Page 3

ANNEXURE - I M/s. Sesha Sai Chemicals Pvt. Ltd., proposed to establish a Synthetic Organic Chemical

Manufacturing Unit at 159/1 (Part), Kandivalasa Village, Pusapatirega Mandal,

Vizianagaram District, Andhra Pradesh. The company acquired 14.8 acres of land for the

proposed plant and allocated 4.79 acres of the area for green belt. Total capital cost of the

project is Rs. 25.5 Crores. The proposed list of products and manufacturing capacity is

presented in Table A-1.

Table A-1 Manufacturing Capacity

S.No Name of then Product Capacity (Kg/day)

Phase I 1 Benzyl chloride 1000 2 Benzyl alcohol 1000 3 Benzaldehyde 1000 4 Benzyl acetate 1000

Total - Phase I 4000 Phase II

1 Amlodipine Besylate 400 2 Amlodipine Maleate 400 3 Carvedilol 300 4 Carvedilol Phosphoate 300 5 Carvedilol RM 300 6 Clopidogrel -Form 1 and Form 2 200 7 Clopidogrel Hydrogen sulfate 250 8 Clopidogrel Intermediate 250 9 Eprosartan Mesylate 300

10 Escitalopram Oxalate 300 11 Flecainide 300 12 Glimepiride 300 13 Lamotrigine 200 14 Lansoprazole 200 15 Levofloxacin Hemihydrate 300 16 Moxifloxacin 300 17 Moxifloxacin Hcl 300 18 Nateglinide Form H 300 19 Nebivolol Hcl 250 20 Norfloxacin 300 21 Olanzapine 250 22 Omeprazole 300 23 Pantoprazole Sodium 300 24 Paroxetine Hcl 250


Page 4

25 Raloxifene Hcl 300 26 Saprofloxacin 300 27 Sertraline Hcl 250 28 Telmisartan 200 29 Thalidomide 200 30 Topiramate 300

Total - Phase II (Worst Case Scenario -Only 4 products) 1400 Grand Total (Phase I + Phase II) 5400

List of By-Products S.No Name of the By Product Quantity

(Kg/day) 1 Benzyl Ether 624.91 2 Benzyl Alcohol 1077.57 3 Benzolic acid 324.78


Page 5

Process Description of Lamotrigine

Stage I

Process Description for Febuxostat

Stage-I:

Water is charged into the reactor followed by amino guanidine bi-carbonate, then cooled.

Sulphuric acid is slowly charged into the reactor and the clear dissolution is checked. 2, 3

Dichloro Benzoyl Cyanide solutions are added into the reactor. And maintained for 30-45

min then cooled. The sample is checked for completion of reaction and maintained for 20

hours then cooled and maintained for 1 hour. The reaction mass is filtered and washed

with UF water and collected stage-1 crude material. Methanol is charged into the reactor

followed by wet material and Caustic Soda Flakes. Mass is stirred for 10-15 minutes, and

heated to reflux then maintained under reflux for 2 hours. The reaction mass is cooled and

the sample is checked for completion of condensation product. The solvent is distilled off

completely under vacuum UF water is charged into the reactor and heated then stirred at

same temperature for 15 to 30 minutes. The reaction mass is cooled and maintained at

same temperature for 1 hour. The mass is filtered and washed with UF water and collected

Stage -1 wet material.

Stage-II:

Methanol is used as a solvent in this stage. Initially Methanol is charged into the reactor

followed by stage-1 wet material. The reaction mass is heated to reflux and maintained

under reflux for 30-45 min then dissolution is checked. The reaction mass is transferred

through Leaf Filter and Cartridge filters and the filtrate is collected into the reactor by


Page 6

applying the Nitrogen and sample is checked for particle free. Distilled off the solvent up

to 70 % of the total volume under vacuum. Then cooled and maintained at same

temperature for 1 hour. The mass is centrifuged and washed with Methanol and collected

stage-2 technical grade wet material i.e. 6-(2, 3-Dichlorophenyl)-1, 2, 4-triazine-3, 5-

diamine and dried. The process flow diagram is presented in Fig A-1 and material

balance is presented in Table A-2.

Fig A-1 Process Flow Diagram of Lamotrigine


Page 7

Table A-2 Material Balance for Lamotrigine Stage I Input Quantity

(Kg/day) Output Quantity

(Kg/day) Remarks

2, 3 Dichloro Benzoyl Cyanide

360.56 Lamotrigine crude 300 To stage 2

Aminoguanidine Bicarbonate

245.2 Aceto Nitrile 360 Recovery:342,Loss:2, Residue:16

Sulphuric Acid 176.68 Methanol 1320 Recovery:1254,Loss:6.4, Residue:20, To waste water:39.6

Caustic Soda Flakes 144.24 Water including Sodium sulphate+ reaction water+ un reacted compounds

5855.12 To waste water

Water 5280 Carbondioxide 51.56 Safely released in to atmosphere

Aceto Nitrile 360 Methanol 1320 Total Input 7886.68 Total Output 7886.68

Stage II Input Quantity

(Kg/day) Output Quantity

(Kg/day) Remarks

Lamotrigine crude 234.52 Lamotrigine 200 Final Product Methanol 8000 Methanol 8000 Recovery:1957,Loss:3,

Residue:40 Process Residue 34.52 Residue Total 8234.52 Total 8234.52


Page 8

ANNEXURE – II: Wastewater Treatment Facilities

The effluent generated from the proposed Synthetic Organic Chemicals manufacturing

unit is mainly from process, washings, and scrubbers, cooling towers & boiler blow downs

and domestic effluent. HTDS effluent sent to Stripper, Multiple Effect Evaporator

followed by ATFD, Biological treatment and RO. LTDS effluent from Cooling towers and

boiler bow downs shall be sent to Biological treatment system followed by RO. The treated

effluent reused for cooling towers make-up. Domestic effluent sent to septic tank followed

by soak pit. Total Effluent generated and mode of treatment before is presented in Table

A-3.

Table A-3 Quantity of Effluent Generated and Mode o Treatment (Tentative)

Description Quantity (KLD) Mode of Treatment Phase I Phase II

HTDS Effluents Process 0.8 47.8 Treated in effluent treatment plant

consisting of Stripper, MEE, ATFD, Biological treatment and RO. RO permeate reused for cooling tower makeup. RO rejects sent to MEE.

Washings 1 3 Scrubber Effluent 2 2

Total - I 3.8 52.8 LTDS Effluents

Boiler Blow downs 1.2 2.3 Sent to Biological Treatment System followed by RO. RO permeate reused for cooling tower makeup. RO rejects sent to MEE.

Cooling Tower Blow downs

4 8

Domestic 4 6.5 Septic Tank followed by soak pit. Total - II 9.2 16.8 Grand Total (I+II) 13 69.6


Page 9

ANNEXURE – III: Water Balance

Water is required for process, scrubbers, washing, cooling tower makeup, steam

generation and domestic purposes. The required water shall be drawn from ground water

sources in addition to reuse of treated wastewater. The total water requirement after

phase II is in the order of 203.22 KLD consisting of 125.72 KLD fresh water and 77.5 KLD

of recycled water. The fresh water requirement for Phase I is 29.87 KLD and 95.9 KLD for

Phase II and treated wastewater reuse for Phase I is 12.5 KLD and 65 KLD for Phase II. The

water balance for daily consumption is presented in Table A-4.

Table A-4 Total Water Balance (Tentative)

Purpose INPUT (KLD) OUTPUT (KLD) Fresh Water Recycled Water Loss Effluent

Phase I Phase II Phase I Phase II Phase I Phase II Phase I Phase II Process 0.37 46.9 0.8 47.8 Washings 1 3 1 3 Scrubber 2 2 2 2 Boiler Feed 8 14 6.8 11.7 1.2 2.3 Cooling Tower 10.5 15 12.5 65 19 72 4 8 Domestic 5 8 1 1.5 4 6.5 Gardening 3 7 3 7 Gross Total 29.87 95.9 12.5 65 29.8 92.2 13 69.6 Total 125.72 77.5 122 82.6 * Process effluents contain soluble raw materials, byproducts, solvents etc.


Page 10

ANNEXURE – IV: Solid Waste

Solid wastes are generated from process, solvent distillation, effluent treatment system,

DG sets and boilers. The stripper distillate, process residue and solvent residue are sent to

cement plants for co-incineration based on acceptability. If these wastes are not suitable

for co-incineration, the same is sent to TSDF facility. The evaporation salts are sent to

TSDF. Filter media like activated carbon and catalyst are sent to TSDF. Waste oil and

used batteries from the DG sets are sent to authorized recyclers. The sludge from effluent

treatment plant is considered hazardous and the same is sent to TSDF. The other solid

wastes expected from the unit are containers, empty drums which are returned to the

product seller or sold to authorized buyers after detoxification. Coal ash from boiler is

sold to brick manufacturers. The total solid waste generated and mode of disposal is

presented in Table A-5.

Table A-5 Solid Waste Details (Tentative) S.No Description Units Phase I Phase II Total

after Phase II

Mode of Disposal

1 Ash from Boiler TPD 1 2 3 Sold to Brick manufactures

2 Process Organic rsidue

TPD 0.14 0.25 0.39 Sent to TSDF/Cement Industries

3 Solvent Residue TPD 1.56 1.56 Sent to TSDF/Cement Industries

4 Process Inorganic residue

Kg/day 0.45 0.45 Sent to TSDF

5 Spent Carbon Kg/day 5 5 Sent to TSDF/Cement Industries

6 Hyflow Kg/day 0.25 0.25 Sent to TSDF 7 Evaporation Salts TPD 0.034 1.51 1.544 Sent to TSDF 8 Stripper Distillate Lts/day 90 1200 1290 Sent to Cement Industries

for Co-incineration. 9 ETP Sludge Kg/day 18 65 83 Sent to TSDF 10 Detoxified

containers No.s/year 500 1000 1500 After detoxification sent

to Authorized agencies 11 Waste oil lts/Month 50 65 115 Sent to Authorized

Recyclers 12 Used batteries No.s/year 1 2 3 Sent to Authorized

Recyclers


Page 11

ANNEXURE – V: Stack Emissions Details

The sources of air emission expected from the plant are 2TPH and 4TPH Coal fired Boilers

in Phase I and Phase II respectively and DG sets of 125 and 250 KVA capacity in Phase-I

and Phase-II respectively. The proposed air pollution control equipment for coal fired

boilers is multi cyclone separators. DG sets shall be provided with stack heights based on

the CPCB formula for effective stack height. The emission rates of SPM, SO2, NOx and

SPM from each stack are presented in Table A-6.

Table A-6 Stack Emission Details S.

No Stack Connected to

Stack Ht (m)

Dia of stack at top(m)

Temp. of exhaust

gases (OC)

Exit Velocity (m/sec)

Pollutant Emission Rate (g/sec)

PM SO2 NOx Phase - I

1 2TPH Coal fired Boiler

21 0.5 180 10 0.06 0.05 0.02

2 125 KVA DG Set 2 0.06 160 9.5 0.01 0.11 0.18 Phase - II

1 4TPH Coal fired Boiler

25 0.8 200 15 0.10 0.11 0.35

2 250 KVA DG Set 3 0.125 150 13 0.02 0.01 0.01 *DG sets will be used during load shut down by APTRANSCO.


Page 12

ANNEXURE – VI: Process Emissions Details

Table A-7 Quantity of Process Emission Generated (Tentative) Product Name of the Gases Quantity

(Kg/Day) Mode of Treatment

Phase I Benzyl chloride Hydrogen Chloride 288.02 To Scrubber

Oxygen 126.39 Safely released in to atmosphere Benzyl Alcohol Hydrogen Chloride 350.83 To Scrubber Benzaldehyde Oxygen 34.95 Safely released in to atmosphere Benzyl Acetate Oxygen 35.51 Safely released in to atmosphere

Phase II Amlodipine Besylate Hydrogen 2.08 Safely released in to atmosphere Amlodipine Maleate Hydrogen 3.08 Safely released in to atmosphere Clopidogrel Intermediate

Carbon dioxide 34 Safely released in to atmosphere

Carbon dioxide 24.9 Safely released in to atmosphere Clopidogrel bisulphate -from 1

Carbon dioxide 42.79 Safely released in to atmosphere Carbon dioxide 31.28 Safely released in to atmosphere Carbon dioxide 20.98 Safely released in to atmosphere

Eprosartan mesylate Carbon dioxide 27 Safely released in to atmosphere Flecainide Carbon dioxide 32.19 Safely released in to atmosphere Hydrogen 2.4 Safely released in to atmosphere Pure Carvedilol Hydrogen 2.1 Safely released in to atmosphere Carbon dioxide 19.86 Safely released in to atmosphere Lamotrigine Carbon dioxide 51.56 Safely released in to atmosphere Nateglinide Form H pure

Sulphurdioxide 126 Sent to scrubber

Hydrogen chloride 71.88 Sent to scrubber Nebivolol Hydrochloric acid

Hydrogen 0.625 Safely released in to atmosphere

Hydrogen chloride 12.5 Sent to scrubber Raloxefine Hydrochloride pure

Sulphurdioxide 57.36 Sent to scrubber

Hydrogen chloride 65.4 Sent to scrubber Setraline HCL Form 1 Hydrogen 5.2 Safely released in to atmosphere Topiramate Carbon dioxide 47.052 Safely released in to atmosphere Telmisartan Hydrogen Bromide 67 Sent to scrubber Thalidomide (Pure) Carbon dioxide 375.28 Safely released in to atmosphere

Ammonia 69.36 Sent to scrubber Carbon dioxide 141.24 Safely released in to atmosphere



STUDIES AND DOCUMENTATION BY TEAM Labs and Consultants QCI: MoE&F OM, List A-1, S.No. 150. (An ISO 9001:2008, ISO 14001:2004 & OHSAS 18001:2007 Certified Organization) B-115, Annapurna Block, Aditya Enclave Ameerpet, Hyderabad-500 038. Phone: 040-23748 555/616, Telefax: 040-23748666 Email: [email protected]

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