M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 1
1.0 EXECUTIVE SUMMARY
M/s. ZCL Chemicals Ltd. is engaged in manufacturing of Pharmaceuticals Intermediates and
Active Pharmaceutical Ingredients at Plot No. 3102/B, GIDC Industrial Estate, Ankleshwar -
393002, Gujarat. Existing Product capacity is 304.9 MT/Year and the proposed capacity after
expansion will be 790 MT/Year.
As per EIA notification 2006 and its amendment, the proposed project is falling under category
5(f). The unit is having CCA for manufacturing of Pharma Intermediates and Active
Pharmaceutical Ingredients.
The details of products are given below table.
TABLE: 1
LIST OF PRODUCTS AS PER EXISTING CCA: AWH-72765
Sr.
No.
Name of Products Existing as per
CCA No.
AWH-72765
(MT/Year)
Group 1 204.3
1 Thrio Pypridil Amide 204.03
Either/ or
product will be
made
2 Ritalinic acid
3 4 - benzyloxy -3- nitrophenylace bromide
4 Zonisamide
5 Modafinil - EP/USP
6 4-Amino-N-[(2 R, 3S)- 3 Amino, 2 hydroxy, 4-
phenyl butyl ] – n – (2 Methyl propyl) benzene
sulfonamide
7 Darunavir
8 Fluvoxamine Maleate
9 Trifluoperazine
10 Methylphenidate
11 R & D Products
12 Dex Methyl Phenidate
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 2
Sr.
No.
Name of Products Existing as per
CCA No.
AWH-72765
(MT/Year)
13 Chlordiazepoxide
14 Cillastazol
15 7 Hydroxy 1,2,3,4 tetra hydro quenoline
16 Chloro Methyl cyclo propane
17 1-(2,3 dichloro phenyl) - piperazine
hydrochloride (DCPP)
18 BBQ (7-(4-Bromobutoxy)-3, 4-
dihydroquinolin-2(1H)-one)
19 T2551 - Etravirin Inter
20 Canagliflozicin Inter (n-2): 2-(4-fluorophenyl)-
5-(5-iodo-2-methylbenzyl)thiophene
21 Aripiprazole
22 BET (1-(2-Bromoethyl)-4-ethyl-1,4-dihydro-
5H-tetrazol-5-one)
23 1-Amino Indane
GROUP – 2 42.03
24 Trimethyl pyruvic Acid AND/OR 42.03
25 4,4’-Diflurobenzhydryl Piperazine
26 2 Tri Pheno trimethyl phenothiazine
27 Levomepromazine
28 Betahistine IP / EP / USP
29 Betahistine Mesylate JP/EP
GROUP – 3 23.1
30 Phenyl 2 Piperidyl Acetamide 23.1
Either/ or
product will be
made
31 N- (1 Benzyl 4 Piperidinyl) N Phenyl
Propanamide HCL / NN Phenyl N 4 Piperidinyl
Propanamide HCl
32 N Acetyl Hydroxy Phenyl Piperazine
33 Amino Ethyl Phosphoric Acid
34 (1-Isopropyl-4-(hydroxyl Phenyl) (piperazine)
35 Memantine HCl
36 Quetiapine Fumerate
GROUP –4 23.266
37 Phenyl 2Pyridyl Acetamide 23.266
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 3
Sr.
No.
Name of Products Existing as per
CCA No.
AWH-72765
(MT/Year)
38 Zaltoprofen Either/ or
product will be
made
39 Alprazolam
40 Mono chloro acetonitrile
GROUP –5 : Individual Product 12.48
41 BOC Nitro 0
42 (N-[4-Methoxymethyl)-1-(phenyl methyl)-4-
Piperdinyl]-N-Phenyl Propanamaide-
Ethanedioate.
0.06
43 Dex Ritalinic Acid 0.1
44 Remi N Benzyl Propeonamide eater Oxalate 0.02
45 Nebivolol 0.1
46 Flurbiprofen 0.4
47 Olanzapine 0.4
48 Levodropropizine 0.5
49 Atomoxetine 0.5
50 Felbiprofen 3
51 Clozapine 1.8
52 Diazepam 0.4
53 Oxazepam 0.4
54 Flupirtine maleate 0.4
55 Bromazepam 0.4
56 Benzhydrl Piprazine 4
Total 304.906
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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TABLE: 2
LIST OF PRODUCT AFTER EXPANSION
Sr.
No Product Name
CAS No. Proposed
quantity
CNS Active API/Intermediates: 225 TPA
225 TPA
Either/ or
product will
be made
1 Thrio Pypril Amide 50288-62- 5
2 Ritalinic acid 19395-41- 6
3 Zonisamide - USP 68291-97- 4
4 Modafinil - EP/USP 68693-11- 8
5 Fluvoxamine Maleate- EP/BP/USP/JP - FLX/MDD 61718-82- 9
6 Trifluoperazine - USP/EP/BP 440-17- 5
7 Methylphenidate - USP/EP 298-59- 9
8 Dex Methyl Phenidate 19262-68- 1
9 Chlordiazepoxide 58-25-3
10 7 Hydroxy Quinoline 22246-18-0
11 1-Chloromethyl cyclopropane 5911-08-0
12 1-(2,3 dichloro phenyl) - piperazine hydrochloride (DCPP) 119532-26- 2
13 7-(4-Bromobutoxy)-3, 4-dihydroquinolin-2(1H)-one (BBQ) 129722-34-5
14 Aripiprazole 129722-12- 9
15 1-(2-bromoethyl)-4-ethyl-1,4-dihydro-5h-tetrazol-5-one
(BET)
84501-67-7
16 1-Amino Indane 34698-41-4
17 4,4’-Diflurobenzhydryl Piperazine 27469-60- 9
18 2 Tri Pheno trimethyl phenothiazine 92-30- 8
19 Levomepromazine 7104-38- 3
20 Betahistine 5579-84- 0
21 Betahistine Mesylate JP/EP - 54856-23-4
22 Phenyl 2 Piperidyl acetamide 19395-39- 2
23 N- (1 Benzyl 4 Piperidinyl) N Phenyl Propanamide HCL /
NN Phenyl N 4 Piperidinyl Propanamide HCl - (FC
1002/1003)
5156-58- 1
24 Memantine HCl 41100-52- 1
25 Quetiapine Fumerate 111974-72- 2
26 Phenyl 2Pyridyl Acetamide 7251-52- 7
27 Alprazolam 28981-97- 7
28 Mono chloro acetonitrile 107-14-2
29 Remi N Benzyl Propeonamide eater Oxalate 61085-73- 2
30 Olanzapine 132539-06- 1
31 Benzhydrl Piprazine 841-77-0
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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Sr.
No Product Name
CAS No. Proposed
quantity
32 Alpha-phenylpiperidine-2-acetic acid (KMP) 19395-41-6
33 Fluvoxamine Oxalate (OXA) NA
34 5-methoxy-p-trifluoromethylvalerophenone-oxime (XIA) 61747-22-6
35 1,2,4-Triazolo[4,3,a]pyridine-3(2H)-one (TZP)
36 4-amino-2-methyl-10H-thieno[2,3b] [1,5]-benzodiazepine
hydrochloride (AMB)
138564-60-0
37 Lurasidone Hydrochloride 367514-88-3
38 2-bromo-3-(2,3-dimethylphenyl)butanal (MPB) 1421259-21-3
39 Brexpiprazole 913611-97-9
40 Nicorandil 65141-46-0
41 Quinfamide 62265-68-3
Group 2- Psychodynamic Substances
42 (N-[4-Methoxymethyl)-1-(phenyl methyl)-4-Piperdinyl]-N-
Phenyl Propanamaide,- Ethanedioate. (SUE / SU 10)
61086-13- 3
25 TPA Either/ or
product will
be made
43 Dex Ritalinic Acid 1382859-13-3
44 Atomoxetine 82248-59- 7
45 Diazepam 439-14-5
46 Oxazepam 604-75-1
47 Flupirtine maleate 75507-68-5
48 Bromazepam 1812-30-2
49 Nebivolol 152520-56-4
50 Levodropropizine - EP 99291-25-5
51 Clozapine 5786-21- 0
52 Eslicarbazepine Acetate 236395-14-5
Anti Asthmatic Intermediates: 40 TPA
53 4 - benzyloxy -3- nitrophenacyl bromide 43229-01- 2 40 TPA Either/ or
product will
be made
54 4-benzyloxy-3-nitrostyreneoxide (NSO) 51582-41-3
55 2-(2[3-(3-[2-(7-chloroquinoline-2-yl)ethenyl)phenyl)-3-
hydroxy-n-propyl]phenyl)-2-propan-1-ol (SMKT)
142569-70-8
Anti Viral API/ Intermediates: 200 TPA
56 Di Amino (BOC 1/ DRV II) 169280-56-2 200 TPA Either/ or
product will
be made
57 Darunavir 635728-49-3
58 T2551 - Etravirin Intermediate 269055-15-4
59 BOC Nitro 191226-98- 9
Antidiabetic API: 100 TPA
60 Canagliflozin Inter (n-2): 2-(4-fluorophenyl)-5-(5-iodo-2-
methylbenzyl)thiophene
842133-18-0 100 TPA Either/ or
product will
be made
61 Dapagliflozin 461432-26-8
62 Empagliflozin 864070-44-0
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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Sr.
No Product Name
CAS No. Proposed
quantity
Antiinflammatory API
63 Zaltoprofen 74711-43- 6
75 TPA Either/ or
product will
be made
64 Flurbiprofen 5104-49-4
65 Felbinac - JP/BP 5728-52- 9
66 Loxoprofen Sodium 80382-23-6
67 Naproxen Sodium 26159-34-2
Miscelleneous groups: 125 TPA
68 Mirabegron 223673-61-8
125 TPA Either/ or
product will
be made
69 Deferasirox 201530-41-8
70 Colesevelam 182815-44-7
71 Tricyclo [3.3.1 13, 7] decan-1- aminium, N, N, N-Trimethyl
hydroxide (TMA)
NA
72 N, N-Dimethyl- 3, 5-dimethyl piperidinium hydroxide (TMP) NA
73 Pirfenidone 53179-13-8
74 Apalutamide (CAP/CBF) 956104-40-8
75 5-chloro-N-({(5S)-2-oxo-3-[4-(3-oxomorpholin-4-yl)phenyl]-
1,3-oxazolidin-5-yl}methyl)thiophene-2-carboxamide
(BAN/Rivaroxaban)
366789-02-8
76 Trimethyl pyruvic Acid 815-17-8
77 N Acetyl Hydroxy Phenyl Piperazine 67914-60-7
78 Amino Ethyl Phosphoric Acid 071-23-4
79 (1-Isopropyl-4-(hydroxyl Phenyl) (piperazine) 67914-97-0
80 Cilastazol 73963-72- 1
81 R & D Products
Total 790 TPA
COST OF PROJECT
Total cost for proposed project is approx. 40 crore. The plot has been purchased by M/s. ZCL
Chemicals Ltd. from GIDC. The total plot area of the unit is 35595 Square meter. The green belt
area is apprx 6200 square meters.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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FUEL CONSUMPTION
The existing unit uses Natural gas as fuel for Boiler & Thermic Fluid heater and diesel used for
DG Set. There will be no changes in proposed project for Natural gas Consumption for Boiler&
Thermic fluid heater, Diesel consumption for DG set.
ELECTRICITY CONSUMPTION
The unit have electricity from Daxin Gujarat Vij Company Ltd. The existing electricity
consumption is 1900 KVA. There will be no changes in Electricity consumption.
WATER CONSUMPTION
The source of water is from GIDC water supply scheme.
The water consumption for industrial purpose is 143.8 KL/day. The water consumption for the
domestic & gardening purpose is 21.2 KL/day fresh water.
After Expansion, the water consumption for industrial purpose will be 344.8 KL/day (284.8
KL/day Fresh + 60 KL/day Recycle). The water consumption for the domestic & gardening
purpose will be 21.2 KL/day fresh water.
WASTE WATER GENERATION
The existing industrial waste water generation is 45 KL/day and domestic waste water is 10
KL/day. 55 KL/day of effluent is treated in ETP. Treated effluent is discharged in to GIDC
Pumping station – B through above ground fixed pipeline leading to the inlet of FETP for further
treatment and its ultimate disposal to deep sea (facility operated by NCT).
After expansion, total waste water generation will be 140 KL/day. 85 KL/day will be recycled in
RO plant and remaining 55 KL/day will be discharged to FETP. Out of 55 kl/day discharged qty,
The industrial waste water is 45 KL/day and domestic waste water is 10 KL/day. Treated effluent
is discharged in to GIDC Pumping station – B through above ground fixed pipeline leading to the
inlet of FETP for further treatment and its ultimate disposal to deep sea (facility operated by
NCT).
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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GASEOUS EMISSION
There is one stack of Boiler (capacity: 3.5 TPH) (one stand-by boiler 5TPH capacity is also
connected with same stack), one stack of Thermic fluid heater (capacity: 4 lac Kcal/Hr.) and
three stacks of three Diesel Engine Generators (capacity: 250,750 & 1010 KVA respectively).
The three D.G. sets will be used in case of emergency only.
Process emission is from two numbers of stacks. There is one stack attached to Reaction vessel
in Plant-4, one stack attached to Reaction vessel in Plant-2. These stacks are connected with
scrubbers (Water + Caustic). There will be no change in process gas emission due to Proposed
Expansion.
HAZARDOUS WASTE MANAGEMENT
There is generation of ETP sludge (339 MT/Year), Carbon Waste (18.25 MT/Year), Distillation
residue (36.5 MT/Year), Discarded containers (43800 Nos/Year or 350.04 MT/Year), Distillation
residue from contaminated organic solvents (0.73 MT/Year), Used/Waste Oil (1.83 MT/Year),
Contaminated solvents not fit for originally intended use (2000 MT/Year), Spent solvent (73 MT
/ Year).
After Expansion, There is generation of ETP sludge (550 MT/Year), Carbon Waste (50
MT/Year), Distillation residue (105 MT/Year), Discarded containers (43800 Nos/Year or 350.04
MT/Year), Distillation residue from contaminated organic solvents (7 MT/Year), Used/Waste
Oil (10 MT/Year), Contaminated solvents not fit for originally intended use (2000 MT/Year),
Spent solvent (613 MT / Year), Wastes or residues containing oil (0.5 MT/Year), Off
specification products (5 MT/Year) and Date-expired products (5 MT/Year).
Mode of Disposal is given in Annexure-XI of Form 1.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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2.0 INTRODUCTION
2.1 THE PROJECT
M/s.ZCL Chemicals Limited has acquired plot no. 3102/B, GIDC Estate, Ankleshwar for
manufacturing of Chemical Pharmaceuticals Intermediates and Active Pharmaceutical
Ingredients. Unit is proposed for expansion at same unit. The list of Existing & Proposed
products is provided in Table -1& 2.
2.2 PROJECT PROPONENT
M/s.ZCL Chemicals Limited was incorporated in the year 1991. They have manufacturing unit
in Ankleshwar. The Company delivers a broad range of advance fine chemical Pharmaceuticals
intermediates and Active Pharmaceuticals Ingredients for pharmaceutical end use and services to
customers around the world. ZCL has been concentrating on Research and Development. The
project proponents are already in market and doing manufacturing and trading of these products.
Quality, Environment, Health and Safety
Policy:
The policy of the company is as under:
Reflecting its Commitment to Global leadeaship and Excellence in Quality, Environment, Health
and Safety , ZCL Chemicals Ltd. Ankleshwar, Manufacturing Advance Intermediates, Active
Pharmaceutical Ingredients and Safety Chemical in having Guidline principles that Comminted
toward Compatancy in Quality, Lead Time , Overall Economic Feasibility through Environment
Health and Safety must satisfy our Esteem Customers.
It is Policy of ZCL Chemicals Ltd. , Ankleshwar, That
All Incident are Preventable, All identified Health Risk are Containable and identified
Environment impacts are Prevented.
Prevent Injuries and Occupational Illness at the Workplace.
Enhance quality, environment, health and safety awareness.
Comply with all Statutary and Regulatory Laws and Regulation for Quality, Environment,
Health and Safety
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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Continual improvement towards Quality, Technology, after Sale Service Aspect and Upgration
of Environment, Health and Safety Management system to Prevent/Minimize Pollution,
Occupation Health and Safety risks.
Enhance Visibility of Top Management towards Conservation Resource Quality, Environment,
Health And Safety.
Our Quality, Environment, Health and Safety Consciousness shall be Recognised through
acheiving excellence implementation level of ISO 9001 : 2008, ISO 14001: 2004 and Oshas
18001 : 2007 Norms.
The name and address of Directors are given in Table 3.
TABLE: 3
CONTACT DETAILS OF THE DIRECTORS
Sr. No. Name & Address of Directors Designation Contact detail
1 Mr. Ajay Krishnakant Parikh
Managing Director 20/301, Gurukrupa,
Vithal Nagar, CHS Ltd.,
11th Road, JVPD
Scheme, Vile Parle (W),
Mumbai – 400 049
Phone No. - 022—
61539900
2 Mr. Nihar Ajay Parikh
Executive Director 20/301, Gurukrupa,
Vithal Nagar, CHS Ltd.,
11th Road, JVPD
Scheme, Vile Parle (W),
Mumbai – 400 049
Phone No. - 022--
61539906
3 Mr Dhiren Shevantilal Shah
Non-Executive
Director,
Independent
Director
Cumbala Hill post Office,
Gamdevi P.Stn, Mumbai
– 400026.
Phone No. - 022—
61539999
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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4 Mr. Piyush Maganlal Nathwani
Executive Director F 14, Shashwat Complex,
Dahej By Pass Road,
Bharuch-392001, Gujarat
Phone No. - 02646--
619405
5
Ms. Anuja Ajay Parikh
Non-Executive
Director
20/301, Gurukrupa,
Vithal Nagar Society,
11th Road, JVPD
Scheme, Vile Parle (W),
Mumbai-400049.
Phone No. - 022—
61539999
6
Mr. Hargovind Rathore
Non-Executive
Director,
Independent
Director
7 Mr. Ling Wei Ong Non-Executive
Director
2.3 NATURE OF PROJECT
It is Expansion Project.
2.4 MARKET FEASIBILITY
Established in 1991, ZCL Chemicals Ltd (ZCL) is head quartered in Mumbai. The cGMP
manufacturing facility and state-of-the art R&D Center are located in the Industrial park of
Ankleshwar in Gujarat State. ZCL combines the power of Science & Technology and has been
into manufacturing of Active Pharmaceutical Ingredients (APIs) and Advance Intermediates for
Innovator and Generic companies around the world. Has earned the preferred partner status from
some of the Global Pharmaceutical companies.ZCL production site has been successfully audited
and approved by the US FDA, KFDA, WHO-GMP and Japanese customers.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 12
It is a policy of ZCL CHEMICALS LTD, That Commitment towards competency in Quality,
lead time and overall economic feasibility must satisfy our esteemed customers.
Continual improvement towards technical and after sales service aspects of all products shall be
our motto. Renovation towards the best shall be equally participated from all our employees to
drive the organization towards achieving further success & growth in business.
Our quality system is based on ICH Q7 GMP requirements.
Our quality consciousness shall be recognized through achieving excellent implementation level
of ISO 9001:2000; ISO 14001:2004, OHSAS 18001:2007 Norms.
2.5 EMPLOYMENT GENERATION DUE TO THE PROJECT
The details are given below
TABLE: 4
DETAILS OF MANPOWER
Sr.
No. Phase of Project Type of Labor No. of Worker
1 During construction Contractual 150
2 During
commissioning Contractual
NA (existing
manpower shall be
used)
3 During operations
Managerial 210
Skilled 50
Un-skilled 140
Total: 400
3.0 PROJECT DESCRIPTION
3.1 TYPE OF PROJECT
The proposed project is not including any interlinked and interdependent projects.
3.2 PROJECT LOCATION
The proposed project site is located at Plot No. 3102/B, GIDC Industrial Estate, Ankleshwar,
Dist. Bharuch in the state of Gujarat. It is approximately 20 km distance from district head
quarter Bharuch. The approximate geographical positioning of the project site is at Latitude: 21o
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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37’ 36” N, Longitude: 73o01’ 58” E. The location of the project site can be identified from the
location map shown in Figure -2.
The salient features of the location of the project site are presented in below Table.5.
TABLE: 5
SALIENT FEATURES OFTHE PROJECT SITE
Particulars Details
Village Ankleshwar
Taluka/ Tehsil Ankleshwar
District Bharuch
Approx. Geographical positioning Latitude: 21o 37’ 36” N
Longitude: 73o 01’ 58” E
Nearest City Bharuch about 20 KM
Nearest Town Ankleshwar
Nearest Highway National Highway No. 8
Nearest State highway National Highway No. 8
Nearest Railway line/ Railway
station
Ankleshwar Railway Station
Nearest Airport/ Airbase Vadodara about 94 KM
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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FIGURE: 1
LOCATION OF THE PROJECT SITE
Ankleshwar Industrial area
Panoli Industrial area
Jhagadia industrial area
Priaman CETP
Canal
Piraman to Katiyajal Effluent
Pipe
Jhagadia to Piraman CETP
Panoli to Piraman CETP
PROJECT SITE
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Page 15
FIGURE: 2
AERIAL VIEW OF THE 5 KM RADIAL PERIPHERY FROM THE PROJECT SITE
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 16
3.3 SITE SELECTION
The expansion will be done at existing unit. Unit has not consider any alternative site.
3.4 NEIGHBOURING INDUSTRIES
The industry is located in an area, which is already industrialized. The industries in the vicinity
of the proposed project are given in the table 5:
TABLE: 5
NEARBY INDUSTRIES IN THE VICINITY
Name of Industry Direction with respect
to project site
Address
United Phosphorus
Limited (Unit- 2)
East side of company Plot No. 3405/3406, GIDC Industrial
Estate,Ankleshwar-393002
Glenmark
Pharmaceutical
Ltd.
North side of company Plot No. 3109/C, GIDC Industrial Estate,
Ankleshwar-393002
RPG Life Sciences
Limited.
South side of company Plot No. 3102/A, GIDC Industrial Estate,
Ankleshwar-393002
United Phosphorus
Limited (Unit- 3)
West side of company Plot No. 3101/2, Ankleshwar GIDC,
Ankleshwar - 393002
3.5 SIZE OF PROJECT
The expected cost of proposed project is Rs. 40 Crore.
The following table shows the break-up of the project cost.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 17
TABLE:6
CAPITAL COST OF PROJECT
Sr.
No.
Activities Capital cost in
Rs. Crore (Approx)
1. Land Existing land
2. Building 12
3. Plant and Machinery 21.69
4. Q.A. Lab set up ---
5. Env. Protection & Safety
a) Effluent treatment Plant
5.0 b) Air pollution control & Hazardous waste
management
c) Safety Equipment (PPE, fire extinguishers,
Ventilation, etc.)
1.0
d) Green belt development 0.31
Total 40
3.6 PROCESS TECHNOLOGY
Process details like process description for each grade of products are covered separately in
Annexure-VI of Form-I.
3.7 RAW-MATERIALS
The required raw materials will be purchased from the local/ Indian market& foreign market.
Details of raw-material consumption are covered in Annexure-V of Form-I.
3.8 RESOURCE OPTIMIZATION/RECYCLING AND REUSE
3.8.1 SOLVENT RECOVERY
Unit will follow solvent guideline & will recover more than 96% solvent.
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M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 18
3.9 RESOURCE REQUIREMENTS
3.9.1 LAND
The plot had been purchased by M/s.ZCL Chemicals Limited from GIDC. The total plot area of
the unit is 35595 sq. m.
3.9.2 BUILDING
The new building will be constructed. The approximate requirement or construction materials are
given below table. Details are provided in plant lay out.
TABLE 6
APPROXIMATE REQUIREMENT OF CONSTRUCTION MATERIALS
Material Qty. Source
Bricks 2.09 Lacs no. From local
supply
Cement 12372 Bags
Sand 307 Brass.
TMT Steel 145 MT
Kapchi 383 Brass.
3.9.3 POWER AND FUEL
The unit’s power and fuel requirement is provided in Table 7. There will not be any increase in
fuel consumption.
TABLE: 7
POWER AND FUEL REQUIREMENT
Sr.
No.
Particulars Existing as per
Consent Quantity
Proposed
Quantity
Total Quantity Source
1.
Natural Gas for
Boiler & Thermic
Fluid Heater
290 M3/Hrs NO CHANGE 290 M3/Hrs. Gujarat Gas
2. Diesel For DG
Sets 117 Lit./Day NO CHANGE 117 Lit./Day
Local
Supplier
3. Energy-Electricity 1900 KVA NO CHANGE 1900 KVA DGVCL
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M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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3.9.4 WATER
The category wise bifurcation of the water requirement is given in Table no 8. The source of
water will be from GIDC water supply scheme. There will be no change in Proposed Water
consumption.
TABLE:8
DETAILS OF WATER CONSUMPTION
Particulars
Existing water
consumption
(KL/Day)
Proposed
consumption
(KL/Day)
After expansion
consumption
(KL/Day)
i) Domestic +
Others (gardening
etc)
21.2 0 21.2
Process 25 15 40
Boiler 12 40.5 52.5
Cooling 64.8 119.5 184.3
Washing 42 26 68
Total 165 201 366
3.9.5 MANPOWER
The manpower required for the project as well as during the construction/commissioning
activities will be employed from the local area. The details are provided in Table 3.
3.10 MITIGATION MEASURES & EMP
Based on overall manufacturing & operation activities, the mitigation measures have been
proposed by the company for the control of the anticipated pollution load.
3.10.1 WASTEWATER MANAGEMENT
The category-wise bifurcation of the anticipated wastewater generation details is given in Table 9.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 20
TABLE:9
DETAILS OF WASTEWATER GENERATION
Particulars Existing Wastewater
generation (KL/Day)
Proposed
Wastewater
generation (KL /Day)
After Expansion
Wastewater generation
(KL /Day)
i) Domestic+
Others
(gardening etc)
10 0 10
i) Industrial
Process 14 16 30
Boiler 4 0 3
Cooling 3 0 4
Washing 24 44 68
RO reject 0 25 25
Total 55 85 140
3.10.1.2 WASTEWATER CHARACTERISTICS
Industrial wastewater will be generated from process, cooling tower and boiler. The expected
characteristics of industrial wastewater are provided in Table 10.
TABLE: 10
WASTE WATER CHARACTERISTICS
Sr.
No. Parameters Units
Standards
prescribed
by GPCB
Standards
prescribed
by NCTL
Before
Treatment
After
Treatment
1 pH -- 5.5 to 8.5 5.5 to 8.5 6- 9 6.5-8.5
2 Colour Pt Co 100 -- 400-1000 50-70
3 Total Suspended Solids mg/l 100 -- 4500-5500 30-60
4 Total Dissolved Solids mg/l 2100 -- 30000-
35000 1000-2300
5 Oil & grease mg/l 10 -- 8-11 Not
detected
6 Phenolic compounds mg/l 1 -- 1-3 Not
detected
7 Cyanides mg/l 0.2 -- Not
detected
Not
detected
8 Ammonical Nitrogen mg/l 50 100 600-800 30-75
9 Sulphate mg/l 1000 -- 5000-6000 200-300
10 B.O.D.(3 days at 27°C) mg/l 30 -- 5000-
10000 55-70
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 21
11 C.O.D. mg/l 100 1000 30000-
35000 50- 350
3.10.1.3 WASTEWATER TREATMENT & DISPOSAL
EFFLUENT TREATMENT SCHEME
HIGH STRENGTH EFFLUENT STREAM:
Following measures shall be adopted to reduce the strength of waste water —
� PRE-TREATMENT
The effluents from various plants will be collected in individual sumps/tanks and will be
equalized in Collection Tank. They will be neutralized in Neutralization tank by using acid or
alkali as per requirement till required pH range obtained. This neutralized effluent will be filtered
through Filter Press. This will be passed through clarifier after pH increase by alkali and
Settleable solids will be separated out. The supernatant will be neutralized using acid and fed to
stripper.
� TREATMENT
The filtered effluent will be fed to Solvent Stripper for Recovery of solvents. This stream
afterwards shall be subjected to Multiple Effect Evaporator (MEE) (Under Vacuum
Evaporation). Condensate shall be transferred in O & G Chamber for further treatment at ETP.
The concentrated stream (recycle) will be transferred to Agitated Thin Film Dryer (ATFD) for
drying salts and bagging. This will be stored in hazardous Waste Storage Yard and disposed of
for landfilling to TSDF’s as per requirement.
LEAN STRENGTH STREAM EFFLUENT:
The lean effluents will comprise of utility blowdown, MEE condensate, Reject water, etc. They
shall be mixed with other streams and the combined effluent shall be subjected to following
treatment cycle.
� PRIMARY TREATMENT
1. Screen, Oil and solvent trap: - This will ensure removal of free and floating material, oily
material and solvents. These are to be removed manually. The oil and solvent trap unit operation
shall work on gravity separation principle.
2. Equalization cum Neutralization tank: - The effluent after removal of screenings, oily matter /
solvents shall be collected in equalization cum neutralization tank. Suitable mixing device (flash
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 22
mixer) shall be used to mix the contents of the tank. Acid and alkali shall be used as per the
incoming effluent pH. A pH of 7 to 8 shall be maintained here.
3. Tube Settler: - This will be used to remove the Settleable solids from the effluent by
sedimentation process and the effluent will be further transferred to Anoxic tank.
� SECONDARY TREATMENT
Biological Treatment: The biological treatment consist of an Anoxic tank to remove excess
Ammonical nitrogen from effluents. It will be followed by Aerobic process. There are two
aeration tanks with diffused aeration system. The oxygen supply shall be done by use of air
blower and air bubble diffusers. Suitable levels of mixed liquor suspended solids (MLSS) shall
be maintained in the aeration system as per detailed biological process design. The excess
biological sludge shall be discharged over to the sludge handling system via two clarifiers
connected with each aeration tank.
� TERTIARY TREATMENT
Partial Quantity of treated effluent after biological treatment shall be collected and transferred to
Treated Effluent Collection Tank for disposal to FETP. This will be pumped in overground
pressurized pipelines to GIDC pumping stations. Rest of the treated effluent shall pass through
Activated carbon filter, Multi Grade Sand filter. This effluent will be fed to UF and RO plants.
The reject will be added to MEE feed and permeate will be recycled back to Cooling Towers,
Scrubbers, water ejectors, etc. for further reuse.
� SALT/SLUDGE TREATMENT
Salt/Sludge handling system: The system shall consist of VTFD, filter press and decanter
centrifuge. The salt/sludge shall be dewatered/dried and salts/sludge cake shall be bagged. They
shall be stored in Hazardous Waste Storage Yard and disposed of to TSDF’s as per requirement.
� HAZARDOUS WASTE TREATMENT
The Hazardous waste generated from various plant processes will be collected, segregated and
stored at Hazardous Waste Storage Yard. They will be disposed to TSDF’s, Registered
Recyclers, Refiners, Co-processing Units, etc. complying all legal requirements.
MEE OPERATION PROCEDURE
Effluent Feeding:
Neutralized effluent (High COD) from neutralization tank after passing through filter press shall
be brought for treatment through pipeline in balance tank at MEE plant.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 23
Pre Heaters
This effluent will be pumped to Pre-heater 3, 2, 1 in series and finally to stripper column via
MEE feed pump with a flow of 1900-1950 Lit/Hr. and finally to solvent stripper column through
pumping under vacuum.
Main Steam application
After starting feed pump gradually open TVR Valve and maintain high steam pressure around
4.0 Kg/Cm2.
Solvent stripper Unit
Start Solvent stripper column pump and maintain solvent stripper column level (Half level of
side glass) through adjustment of valve of Reboiler & recycle valve. Open Low pressure steam
valve gradually for solvent stripper column/re-boiler and maintain Temp around 85 oC. When
desired temp. attained in stripper column/Reboiler start condensate pump and transfer low boiler
vapor condensate via surface condensers to Stripper condensate collection tanks. The residual
high boiler effluent will be transferred to Calendria 1.
Calendria’s
After receiving high boiler effluent start Calendria pump No. 01, 2, and 3 in successions after
necessary level is maintained in calendria’s. During level maintenance apply steam gradually and
maintain upto 8.0 Kg/cm2.
Condensate Pump
After full steam is applied in MEE, MEE condensate pump is started and the condensate received
via MEE surface condensor (primary and secondary) is recirculated back in balance tank till
colour of the condensate is clear, colourless & free from any suspended solids. Then transfer this
condensate water in MEE O/L collection tank via MEE condensate pump.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 24
Recycle Pump
The remaining concentrated mass will be transferred after checking Baume (specific gravity) in
VTFD Balance Tank via recycle pump for further drying process in VTFD.
VTFD Unit
Start VTFD vacuum pump ensuring cooling circulation via vacuum Syntax pump.
The concentrated mass is kept agitated in VTFD Balance tank and is fed in VTFD agitator via
VTFD feed pump. Simultaneously open high pressure steam valve for VTFD and Maintain
steam pressure 8.0 – 8.5 Kg/cm2 gradually.
Start main VTFD Agitator and set the valve opening such that dry powder/salt is received at the
bottom end. Start Condensate pump and transfer condensate received from VTFD surface
condensor to E.T.P.
Collect dry powder/salt in drum from VTFD bottom hopper. Fill this powder/salt in empty bags
and shift to Haz Waste storage yard and dispose to TSDF time to time.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 25
TABLE: 11
DEMENTIONAL DETAILS OF ETP UNITS
DIMENSIONAL DETAILS OF ETP UNITS
Sr.
No. Name of Equipment Capacity
Retention
time in Hrs. MOC
1 Collection Tank 66 KL 26.4 RCC
2 Neutralization Tank 41 KL 16.4 RCC
3 Filter Press 10 M3/hr - MS
4 Filter Press Tank 05 KL
RCC
5 MEE Plant - Old 40 M3/Day - SS
6 MEE Plant - New 80 M3/Day SS
7 Stripper I/L Clarifier 26 KL RCC
8 O & G Chamber 1.70 KL RCC
9 Neutralization Tank 3 KL RCC
10 MEE O/L Collection Tank (New Eq.
Tank)
61 KL 14.4 RCC
11 Tube Settler 27 KL 0.17 RCC
12 Anoxic Tank 19 KL RCC
13 Aeration tank-1 463 KL 84 RCC
14 Primary Clarifier 26 KL RCC
15 Aeration Tank-2 409 KL RCC
16 Secondary Clarifier 26 KL RCC
17 New Final Treated Effluent Tank 10 KL RCC
18 Activated Carbon Filter (ACF) FRP *** *** FRP
19 Multi Grade Filter (MGF) FRP *** *** FRP
20 Ultrafiltration Plant (UF) (PVDF) 100 M3/Day SS
21 UF Permeate Tank 5 KL HDPE
22 Reverse Osmosis Plant (RO) 100 M3/Day SS
23 RO Permeate Tank 5 KL HDPE
24 Secondary O/L Collection tank 40 KL RCC
25 Holding Tank 12 KL 2.4 MS
26 Treated Effluent Tank 165 KL 72 RCC
27 MEE Cooling Tower - Old 70 TR RCC
28 MEE Cooling Tower - New 400 TR RCC
29 VTFD – Old 160 Kg/Hr. SS
30 VTFD - New 215 Kg/Hr. SS
31 Decanter Centrifuge 2 M3/Hr. SS
32 Decanter Feed tank 2 KL RCC
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 26
FIGURE:3
FLOW DIAGRAM OF ETP
Dosing System
Stripper Condensate to Incineration / MEE C.T
MEE Condensate to New Eq. Tank (L.COD)
MEE Concentrate to VTFD / Storage Tanks
VTFD Salt to TSDF after bagaging
EFFLUENT TREATMENT SCHEME - ZCL CHEMICALS LIMITED
By gravity from
QC and R & D
and from U-3 & U-
1 sump via
pumping
LCOD effluent
from U-4
U-4 H.COD &
L.COD Sumps via
pumping
Sewage Effluent
From U-3 & U-1
sump via
pumping
REJECT
EFFLUENT
TO MEE
PERMEATE TO
REUSE IN C.T.'S,
UTILITIES
U-2 (NPC) sumps
via pumping
Low COD
Effluent from
Utilities
To Final
Discharge
Tank
(165 KL)
U-2 (NPC)
Sumps via
pumping
Sludge to
TSDF
To NCT (FETP)To Deep Sea
Decanter Feed
Tank
Sludge after
bagaging to
TSDF
Decanter
Centrate to
Low or High
COD Eq. Tank
To GIDC
Pumping
Station-B
Collection Tank(66 kl)
U-3 + U-1 effluent
tank T-03(10 kl)
Unit-2 effluent
tank T-02(10 kl)
Unit-2 effluent
tank T-01(10 kl)
Neutralization Tank(41 kl)
MEE PLANT with solvent stripper &
ATFD(80 KL/Day)
MEE PLANT with solvent stripper &
VTFD
Low COD Equalisation Tank
Neutralization Tank
with flash mixer
O & G Chamber
Aeration tank-1 (463 KL)
Anoxic Tank
(19 KL)
Settler(27 KL)
Primary Clarifier(26 KL)
Aeration tank-2 (409 KL)
Secondary Clarifier
Treated Effluent
Collection Tank
M
G
F
A
C
F
UF & RO Unit
Decanter
Centrifuge
QC + Unit-1 +
R & D + effluent
tank T-07(10 kl)
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 27
FIGURE :4
FLOW DIAGRAM OF MEE
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 28
3.10.2 GASEOUS EMISSIONS & CONTROL
3.10.2.1 FLUE GAS EMISSION
There will be flue gas emission from one Boiler, Thermic fluid heater and three DG sets. Natural
gas will be used as fuel and diesel will be used as fuel in DG set. The air pollution control
measures are covered in below table 12.
TABLE:12
DETAILS OF FLUE GAS EMISSIONS
Sr.
No.
Stack
Attached
To
Stack
Heigh
t
Stack
Diameter
Fuel
Consumption
Air
Pollution
Control
System
Type
of
Emission
Permissible
Limit
Existing Flue gas Emission As per CCA
1. Boiler
3TPH 30 m
0.45m
(Top) Natural gas --
PM
SO2
NOx
150
mg/NM3
100 PPM
50 PPM
2. Thermic
fluid heater 22 m
0.5m
(Top) Natural gas --
3. DG Set-1
(250 KVA) 7 0.15m Diesel --
4. DG Set-2
(750 KVA) 8 0.2m Diesel --
After Expansion Flue gas Emission
1.
Boiler*
5TPH
(Stand By) 30 m
0.45m
(Top)
Natural gas --
PM
SO2
NOx
150
mg/NM3
100 PPM
50 PPM
2. Boiler
3TPH Natural gas --
3. Thermic
fluid heater 22 m
0.5m
(Top) Natural gas --
4. DG Set-1
(250 KVA) 7 0.15m Diesel --
5. DG Set-2
(750 KVA) 8 0.2m Diesel --
6. DG Set-3*
(1010 KVA) 30 M 0.2 m Diesel --
* Boiler (5TPH)(Stand By) and DG Set-3 (1010 KVA) applied for CTE. The application
No. is 118851 in XGN
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 29
3.10.2.2 PROCESS EMISSIONS
The process emissions from the proposed manufacturing activities are given in Table 13.
TABLE:13
DETAILS OF PROCESS EMISSIONS
Note: There will be no change in proposed process emissions due to Proposed Project.
3.10.3 HAZARDOUSWASTE MANAGEMENT
The following type of hazardous waste will be generated from the operational activities. All the
waste will be stored separately in a designated storage area.
Sr.
No.
Stack
Attached
To
Stack
Height
(m)
Stack
Diameter
(m)
Air Pollution
Control System
Type of
Emission
Permissible
Limit
As per Existing
1. Reactor Vessel
Plant - 4
25 0.15 Water Scrubber +
Caustic Scrubber
HCl
SO2
CL2
20 mg/Nm3
40 mg/Nm3
9 mg/Nm3
2. Reactor
Vessel Plant -
2
21 0.15 Water Scrubber +
Caustic Scrubber
HCl
CL2
NH3
20 mg/Nm3
9 mg/Nm3
175 mg/Nm3
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 30
TABLE:14
DETAILS OF HAZARDOUS WASTE GENERATION
Sr.
No.
Processes as per
Schedule-1
Name of Waste
as per
Schedule-1
Type of waste Cat.
Quantity for Financial
Year
Method of disposal Existing
quantity
in
MT/Year
After
Expansion
Quantity in
MT/Year
1 Purification and
treatment of exhaust
air/gases, water and
waste water from the
processes in this
schedule and
common industrial
effluent treatment
plants (CETP’s)
Chemical sludge
from waste water
treatment
ETP Sludge 35.3 339 550 Collection, storage within
factory premises, transportation
and final disposal at TSDF
M/s.BEIL, RSPL,SEPPL
2 Purification process
for organic
compounds /solvents
Spent carbon or
filter medium
Carbon Waste 36.2 18.25 50 Collection, storage within
factory premises, transportation
and incineration /Co-
processing at TSDF M/s.
BEIL, RSPL & Ambuja
Cements/ other cement plants
3 Production and/or
industrial use of
solvents
Distillation
residues
Distillation
residue
20.3 36.5 105 Collection, storage within
factory premises, transportation
and landfill/incineration/co-
processing at TSDF M/s.
BEIL, RSPL & Ambuja
Cements/other cement plants
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 31
Sr.
No.
Processes as per
Schedule-1
Name of Waste
as per
Schedule-1
Type of waste Cat.
Quantity for Financial
Year
Method of disposal Existing
quantity
in
MT/Year
After
Expansion
Quantity in
MT/Year
4 Handling of
hazardous chemicals
and wastes
Empty barrels/
containers/liners
contaminated
with hazardous
chemicals/wastes
Discarded
containers/liners
33.1 350.04 350.04 Collection, storage with in
factory premises, transportation
and sell to authorize agencies.
5 Hazardous waste
treatment processes,
e.g. pre-processing,
incineration and
concentration
Concentration or
evaporation
residues
Distillation
residue from
contaminated
organic solvents
37.3 0.73 7 Collection, storage within
factory premises, transportation
and landfill/incineration/co-
processing at TSDF M/s.
BEIL, RSPL & Ambuja
Cements/other cement plants
for Co -processing.
6 Industrial operations
using mineral or
synthetic oil as
lubricant in
hydraulic systems or
other applications
Used or spent oil Used / Waste Oil 5.1 1.83 10 Collection, storage, treatment
within factory premises,
transportation and sell to
registered refiners
7 Production and/or
industrial use of
solvents
Contaminated
aromatic,
aliphatic or
napthenic
solvents may or
may not be fit
for reuse.
Contaminated
solvents not fit
for originally
intended use
20.1 2000 2000 Collection, storage, recovery
and reuse within premise at
site. Disposal at TSDF/
Incinerator.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 32
Sr.
No.
Processes as per
Schedule-1
Name of Waste
as per
Schedule-1
Type of waste Cat.
Quantity for Financial
Year
Method of disposal Existing
quantity
in
MT/Year
After
Expansion
Quantity in
MT/Year
8
Spent solvents Spent solvent 20.2 73 73 Collection, storage, recovery
and reuse within premise at
site. Disposal at TSDF/ Co-
processing / Incinerator.
9 Spent solvents Spent solvents 20.2 540 540 Collection of High COD waste
from MEE Stripper Column,
storage, recovery, reuse within
premise at site and disposal at
TSDF/ Incinerator./ co-
processing
10 Industrial operations
using mineral or
synthetic oil as
lubricant in
hydraulic systems or
other applications
Wastes or
residues
containing oil
Wastes or
residues
containing oil
5.2 NA 0.5 Collection, storage,
transportation and sell to
registered refiners &/or
incineration at TSDF M/s.
BEIL, RSPL
11 Production /
formulation of drugs/
pharmaceutical and
health care product
Off specification
products
Off specification
products
28.4 NA 5 Collection, storage within
factory premises, transportation
and incineration at TSDF M/s.
BEIL, RSPL & Ambuja
Cements for Co -processing.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 33
Sr.
No.
Processes as per
Schedule-1
Name of Waste
as per
Schedule-1
Type of waste Cat.
Quantity for Financial
Year
Method of disposal Existing
quantity
in
MT/Year
After
Expansion
Quantity in
MT/Year
12 Date-expired
products
Date-expired
products
28.5 NA 5 Collection, storage within
factory premises, transportation
and incineration at TSDF M/s.
BEIL, RSPL & Ambuja
Cements for Co -processing.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 34
3.10.4 NOISE CONTROL & ODOUR
The major noise generating installation will be the D.G. Set. It will be installed in a closed room,
acoustic enclosure will be provided around it.
Ear plugs will be provided to the operating personnel in boiler room. Low noise generating
equipments will be selected. Adequate engineering controls will be implemented to avoid noise
pollution.
The following steps will be taken for odor control.
• Raw-material feeding will be carried out by pumps and in close loop system.
• All reactions will be taken in closed reactor system.
• Roof top ventilation will be provided in the entire plant area.
• Regular monitoring will be done of piping and fittings for checking of any leakages.
3.10.5 STORAGE, HANDLING AND TRANSPORT OF HAZARDOUS
CHEMICALS
The storage and mode of transport of chemicals will be done as per detailed MSDS and chemical
hazards guide for the hazardous chemicals.
Few chemical to be used in the proposed activities are listed as ‘Hazardous Chemicals’ as per the
Schedule-1 of the MSIHC Rules, as amended in 2000.
3.10.6 HEALTH AND SAFETY MEASURES
Few chemical to be used in the activities are listed as ‘Hazardous Chemicals’ as per the
Schedule-1 of the MSIHC Rules, as amended in 2000.
Physical hazards may manifest as fires, explosions, excessive temperatures, or the release of
large volumes of gas or toxic or flammable gases or vapors. According to Schedule 2 & 3 of
MSIHC Rules.
Below mentioned is the safety measure to be taken at site for control of anticipated hazards.
Identification, analysis, assessment of hazards and risk provides vital information to risk
management. Objective of this plan is to assess the risk and to provide guidelines for facing and
controlling the emergency.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 35
This contains the information of possible hazards and their effects on the workers, general public
and environments.
• Hazards in storage area :
Following are possible storage hazards
� Fire
� Explosion
� Spillage / leakage
� Failure of storage tanks
Most of the chemicals are toxic in nature other than some exception. Toxic substances affect in
three ways by ingestion, absorption and inhalation. Adequate provision of safety is done to work
with toxic materials.
� All raw materials, solvents, intermediates and finished goods are stored
according to their compatibility with other chemicals. The various places
where chemicals, solvents are stored are :
- Licensed tank farm area
- Raw material store
- Cold Room
- WIP room
- Bonded store
� All the flammable liquid materials are stored in storage tanks. The tank
farm for Petroleum Class A, B & C liquids is approved by Chief
Controller of Explosives after due inspection.
� The storage tanks are mounted above grounds with bund. Bund capacity is
1.1 times higher than biggest tank.
� The other chances of fire hazard may be due to generation of static
electricity due to flowing of solvent in the pipeline by accumulating
electrical charge & resulting spark. For this, company has provided
adequate number of static jumpers on each flange joints with proper
earthing.
� For vehicles like tanker, which carry flammable solvents, an additional
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 36
facility is provided at gate house for dissipation of static charge generated
by the tanker while coming to company from its supplier’s location.
� Rule of no smoking is observed strictly in the company premises.
Company has implemented “No Smoking Policy” and at appropriate
places, boards are displayed.
� All the safety standards & parameters are observed strictly. The total area
is provided with adequate firefighting equipment also.
� Earthing facility is provided at the unloading point to provide earthing to
the tankers at the time of unloading.
� Flame arrestor is provided on the vents of tanks containing flammable
liquid.
� The tankers are provided with the flame arrestors (mufflers) while
entering inside the factory premises.
� The raw water tanks with capacity 250 M3.
� Water sprinkler provided on the tanks containing the flammable liquid in
tank farm area.
� The employees are trained in first aid fire fighting.
� Adequate SOPs are in place for safe handling of chemicals and concerned
employees are trained for the same.
� Spillage kit is provided to contain spillage / leakage.
• Fire and explosion
� The fire and explosion risk are associated with
- Solvents like Methanol, Toluene, Acetone, etc.
- Chemicals like phosphorous pentoxide, etc.
- certain chemical reaction like hydrogenation, Grignard, distillation,
� Electrical short circuit
� The fire risk is not affecting outside factory. And hence the risk is limited
to factory area.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
Page 37
� The gas dispersion is Nil.
� To control the fire, fire extinguishers like DCP, CO2 and Foam are
provided. Also, factory has installed the DCP modular in the solvent tank
farm.
� Adequate water tanks having 750 M3 capacities. Facility for water at
several places in plant and factory premises.
� Sprinkler system in tank farm area to control vapour emission and thereby
reduced fire risk.
� Vapor detector system are installed in the warehouse
• Spillage control
� SOP for prevention and control of spillage
- Eliminate all sources of ignition immediately.
- Ventilate the area but isolate the material.
- Absorb the chemical into sand.
- Allow atmospheric evaporation.
- Flush the spilled area with water and detergent.
� Spillage kit for spill control.
� In tank farm area, checking of bund and bund valve is introduced and
being checked regularly.
� Training for spillage control and handling to all employees.
� Fumes and cylinder leakage kit are available.
� All employees are trained for first aid fire fighting and use of personal
protective equipments.
� The duties of responsible persons are as follows :
- To guide the people to stop the leakage and spillage.
- To ensure good housekeeping.
• Technological and civil
Our main products are bulk drug and their advanced intermediates. Considering
the use of hazardous chemicals, following steps are taken.
M/s. ZCL CHEMICALS LTD., ANKLESHWAR
M/s. JYOTI OM CHEMICAL RESEARCH CENTRE PVT. LTD.
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� All structure and other equipments are fabricated as per the engineering
specification laid down in appropriate specification of international and
national bodies in the subject.
� Vessels are equipped with temperature indicators, pressure gauges, level
indicators, safety valves, etc.
� Vessels are pressure tested as per Factories Act, 1948. Flame proof fittings
are provided.
� Regular inspection is carried out by external agency to maintain proper
health of plant, equipment and machinery.
� Thickness of tanks is carried out periodically and record maintained in
Form 11 as per Factories Act.
� Building structure is constructed as per standard practice. Material used is
tested for its quality and suitability under guidance of experts approved
under Government notification.
� The structure is being inspected by Government approved competent
person periodically and stability certificate is maintained.
� Inspection, maintenance, painting of plant / machinery etc, is carried out
regularly.
• Toxic release risk
The potential risk involved is leakage from tanks and pipelines.
To attain the toxic release of gases (DMS and Ammonia) from cylinder, cylinder
leakage control kit is available.
Fumex are available for the dilution of atmosphere inside the plant or used as an
exhaust or in case of tank cleaning it also used as an exhaust fan for fast dilute
Material Safety Data Sheet is kept as ready reference at all critical areas.
Evacuation table is displayed at gate.
Training is given related to Emergency Preparedness to both old and new
employees.
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4.0 SITE ANALYSIS
4.1 CONNECTIVITY
The site is located at Plot no. 3102/B, GIDC Estate, Ankleshwar, Gujarat. The land and
Infrastructure is already available and the raw materials are easily available through the easy
transport via road connectivity.
Ankleshwar Industrial Estate was set up by Gujarat Industrial Development Corporation in early
70s. This industrial estate is spread over an area of 1600 hectares in close proximity to National
Highway No.8 and Delhi-Mumbai Railway Line. Being an ideal location for industrialization, as
on date, more than 1500 industries, consisting of chemicals, pesticides, pharmaceuticals, bulk
drugs, petroleum products, engineering, textiles, plastics, rubber and packaging etc. are located
in this industrial estate.
The town is known for its industrial township called GIDC (Gujarat Industrial Development
Corporation). Ankleshwar has an office of the ONGC (Oil and Natural Gas Corporation
Limited). GIDC is organizing Trade fare and Industrial expo occasionally to attract large number
of industries all over from India. It also helps to get customer on large basis.
Ankleshwar is connected by Indian National Highway 8 (Mumbai to New Delhi) and by the
Western Railway Division of Indian Railways. The railway division also runs the broad
gauge train services to Rajpipla. The 133 year-old Golden Bridge connects Ankleshwar to
Bharuch across the Narmada on the station front while a new bridge connects the highway, the
other bridge on the highway is now ready to use.
Ankleshwar City Bus stand is located on Station Road (i.e. located in the City, the western
section).
Development project of Ankleshwar Airport & City Bus are in pipe line in last stage.
Ankleshwar is an educated city. It has an average literacy rate of 79%, higher than the national
average of 59.5%; with 56% of the males and 44% of females literate.
Ankleshwar JN Rail Way Station, Sanjali Rail Way Station are the very nearby railway station to
Ankleshwar GIDC. However Surat Rail Way Station is major railway station 56 KM near to
Ankleshwar GIDC.
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Healthcare
Hospitals include are the
• Jayaben Modi Hospital,
• Sarvajanik Hospital,
• Sanjivani Hospital
• Sardar Patel Hospital.
• And now ESIC's (Employee State Insurance Corporation) New Hospital is under
Construction.
• In April 2014, the "New Life" private hospital was constructed in Jasaat Plaza (Station
Road). It is conveniently served by Ankleshwar's main bus & railway stations.
Shopping and Recreation:
• There is a lake in GIDC & City area. Situated in front of GIDC Lake, Lakeview Plaza
Mall is city's first truly integrated mall for restaurants, entertainment and hotel stay.
• Nav Graha Jain Mandir (G.I.D.C), Manav Mandir, Sai & Swaminarayan Temple are big
temples in Ankleshwar. Ankleshwar City is also having big Mosques Halimsha Datar
Bhandari, Garib nawaz, etc.
• Centers of Brahma Kumaris World Spiritual University is located in both GIDC and City
area which helps you to know your true self with the help of Free Rajyoga Meditation
Classes.
• There are parks such as The Millennium Park and old parks in Ankleshwar city, the GIDC
Water Reservoir, and sports center.
• There are swimming pools, Joggers Park, children's park, Rotary library and other
recreation centers in the GIDC area.
• There is an Open Air Theater in GIDC Area. Chauta Bazar is the biggest shopping area in
Ankleshwar.
4.2 LAND USE AND LAND OWNERSHIP
The existing project site is located at plot no 3102/B, GIDC Estate, Ankleshwar, Gujarat. The
total plot area of the unit is 35595 Sq. M. Land ownership is with project proponents. The
geographical location is 21o 37’ 36” N latitude and longitude 73o1’ 58” E.
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They have valid consent from Gujarat Pollution Control Board, Gandhinagar. And the consent
no. is AWH-72765 and it is attached as an Annexure-XIII.
4.3 LAND USE
The existing project site is located at plot no 3102/B, GIDC Estate, Ankleshwar, The plot is
notified by GIDC for industrial purpose.
4.4 EXISTING INFRASTRUCTURE
The project is currently located in a well-developed zone, which have all essential facilities such
as well-connected road network with ease of transportation, arrangement for supply of water and
power to industries, effluent disposal facilities etc.
4.5 SOIL CLASSIFICATION
The soils of the district are derived from the Deccan trap which is main rock formation of the
district. The soil of the district can be classified as light, medium and heavy according to depth,
texture and location. There is sandy loam to loamy in texture, brownish black in color.
4.6 CLIMATE DATA
Based on the meteorological data, wind rose have been prepared for the summer season period
between the Oct-2016 to Dec-2016. The wind rose diagram prepared from same data is shown
at Figure 6.
TABLE: 14
METEOROLOGICAL DATA
Month -- Temp. (°C) Relative
Humidity (%)
Rain Fall
mm
October-16 Min. 23 28 0
Max. 35 94 13
Average 29 61 6.5
November-16 Min. 20 24 0
Max. 34 51 10
Average 27 37.5 5
December-16 Min. 17 23 0
Max. 32 52 11
Average 24.5 37.5 5.5
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FIGURE:6
WIND ROSE DIAGRAM FOR PERIOD OF OCTOBER-2016 to DECEMBER-2016
Observation: It was observed that wind is blowing mainly towards the SW direction from NE.
average wind speed was 2.38 m/s with calm winds recorded to be 10.6%.
4.7 SOCIAL INFRASTRUCTURE
Population density and sex ratio of Bharuch District was reported 238 persons/sq.km. and 920
females per 1000 males respectively in 2011 census report. Total literacy of Bharuch District
was found 81.51 %.The basic amenities like primary and secondary education schools,
community health workers, primary health sub centre, private practitioners, primary health
centre, maternity and child welfare, dispensaries, T.B clinic, family welfare centre, hospital,
drinking water, transportation facilities, electricity , telephone etc. are available.
5.0 PLANNING BRIEF
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5.1 PLANNING CONCEPT
Ankleshwar is largely an industrial area dominated by large scale industries, especially chemical
plants& Pharmaceutical plants.
Unit is planning for expansion at existing plot.
Ankleshwar in Gujarat has an industrial area with common effluent treatment plant, common
incinerator and land fill site. Govt. agencies provide many basic facilities like uninterrupted
water supply, power and road network.
5.2 POPULATION PROJECTION
As per provisional reports of Census India, Population of Bharuch District in 2011 is 1,551,019.
Population of male and female are 805,707 and 713,676 respectively. The sex ratio of Bharuch
city is 920 females per 1000 males.
In education section, total literates in Vadodara District are 2,893,080 of which 1,614,087 are
males while 1,278,993 are females. Average literacy rate of Vadodara district is 78.92%.
5.3 LAND USE PLANNING
The proposed project is on a GIDC land.
5.4 ASSESSMENT OF INFRASTRUCTURE DEMAND
The M/s. ZCL Chemicals Ltd. shall get water from GIDC water supply scheme. So there will be
no additional stress on ground water resources and there will be no adverse effect on the ground
water resources available in the nearby area.
5.5 AMENITIES/FACILITIES
The available basic amenities are as under:
(A) Education Facilities:
All the villages have a minimum of one primary school.
(B) Medical Facilities:
All the surrounding villages have medical facilities.
(C) Drinking water Facilities & Power Supply:
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All the villages have potable water supply and in 100% area the drinking water is
supplied through taps, wells and tube wells. All the villages have power supply facilities
in the study region.
(D) Post, Telegraph & Telephone facilities
The information collected clearly indicates that the infrastructural facilities are provided
by respective government agencies for the development of this area. For communication
purpose, post office and phones are available in most of the villages.
(E) Transport Facilities:
Bus services are available in all the villages of the study region within 5 km area and are
the most preferable mode of transport in the region. Auto-rickshaw is also used as
transport facility. Villages are connected with paved roads. All the surrounding area is
covered with 108 emergency facilities.
6.0 PROPOSED INFRASTRUCTURE
6.1 PROCESSING AREA
The process area will cover plant area likeU-1A, 1B, 2, 3, 4, ETP and utilities. The process area
covered by the unit at ground level will be 9510.00 square meter.
6.2 NON PROCESSING AREA
The non process area will cover Electrical panel room, CCOE area, Warehouse-solid & liquid,
TOC Room, 22KV Breaker Room, canteen, U/ground water tanks-all, Cold Room, Security
cabin & OHC Room, HT Yard and surrounding area-utility & main, Admin Block, Scrap yard,
open area near H2 plant, BHP Gully and all roads and passages, contractor sheds, Parking area
etc. The non process area covered by unit at ground level will be around 26085 square meter.
6.3 GREEN BELT
Out of the total land area of 35595 square meters approximately 18% will be utilized for green
belt development. The proposed greenbelt area is 6215.04 square meters.
6.4 SOCIAL INFRASTRUCTURE
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The availability of basic amenities is covered as under:
(A) Training & Education: All the employees will be trained and educated periodically about
the hazardous nature of chemicals used in the process. Also, training for firefighting, work
permit system, first aid, safe handling of hazardous chemicals and integrating safety, in all
activities.
(B) Medical facility: Pre-employment medical checkup at the time of employment. In order to
safe guard the health of the employees, all the employees undergo periodic health checkup.
(C) Drinking water: There will be provision of Aqua Guard/R.O. at different places to provide
purified water for drinking purpose.
(D) Transportation: The unit will provide basic transportation facility for workers.
(E) Telegraph & Post: There will be provision of telephone, fax & internet facility.
(F) Power supply: There will be total connected load of 1900 KVA from DGVCL.
6.5 CONNECTIVITY
Ankleshwar estate is well connected by rail and road to rest of country.
6.6 DRINKING WATER MANAGEMENT
Average daily water consumption of unit will be 10 KL/Day for domestic purpose. The entire
water requirement will be meeting through GIDC water supply system.
6.7 SEWAGE SYSTEM
The sewage will be diverted in soak pit. The overflow of soak pit is treated in ETP.
6.8 INDUSTRIAL WASTE MANAGEMENT
The hazardous waste like ETP sludge, Carbon Waste, Distillation residue, Discarded containers,
Distillation residue from contaminated organic solvents, Used/Waste Oil, Contaminated solvents
not fit for originally intended use ,Spent solvent, High COD waste from MEE stripper will be
generated from the proposed activity. There will be no change in Hazardous waste generation
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due to proposed construction work. The hazardous waste management and disposal is shown in
Annexure-XI in Form-I.
6.9 SOLID WASTE MANAGEMENT
The record of hazardous and non Hazardous waste solid waste like Personal Protective
Equipments, etc
6.10 POWER REQUIREMENT & SUPPLY
The unit will use total 1900 KVA electricity connected load from DGVCL.
7.0 REHABILITATION AND RESETTLEMENT(R &R) PLAN
The proposed project is located in Plot No: 3102/B, GIDC Estate, Ankleshwar, Dist-Bharuch,
Gujarat-393002. There will be no any human settlement affected by proposed project.
8.0 PROJECT SCHEDULE & COST ESTIMATES
8.1 PROJECT IMPLEMENTATION SCHEDULE
TABLE: 16
PROJECT IMPLEMENTATION SCHEDULE
Project implementation schedule
Sr.
No.
Activity Required Period
1. Civil work 10 months
2. Procurement of machinery
3. Erection & installation of machinery after 4 months of completion of building
4. Trial of machinery & equipment within 1 month of above activity
5. Commercial activity within 1 month of above activity
8.2 ESTIMATED PROJECT COST
The proposed project cost will be 40 Crore. Cost bifurcation is given in table 6.
9.0 ANALYSIS OF PROPOSAL
All the manpower is utilized from local region around Ankleshwar. Company shall also try to
provide indirect employment opportunities by availing local contract services during
transportation during operational phase.
CSR activities – Company shall comply with statutory provisions related with CSR activities.