form 1 application form i basic information sl. no. item … · 2017. 6. 15. · e-mail...

Form 1 GCPL 1

FORM 1

APPLICATION FORM

I Basic Information

Sl. No. Item Details

1. Name of the Project : Global Calcium Private Limited. Proposed Augmentation/Expansion

2. S. No. in the schedule : 5 (f) – Pharmaceutical bulk drugs and chemicals.

3. Proposed capacity / area/length/ tonnage to be handled /command area/ lease area / number of wells to be drilled

: Existing Land Area – 2.32 ha. Proposed Expansion & Augmentation within this land area. Existing & Proposed Product / Production Capacity is as Follows

4. New/Expansion/Modernization :

5. Existing Capacity / Area etc. :

Products Existing (in TPA) Proposed (in TPA)

Processing in the Plant

by conventional process Pharmaceutical bulk drugs and chemicals such as Mineral salts of Gluconates, Citrates, Lactates, Lactobionates, Fumarates, Orotates etc

1641

--

by Spray Drier Process Calcium Glubionate , Calcium Borogluconate, Calcium lacto Gluconate, and other Mineral Salts

2615

--

Conventional / job work by conversion (Conventional process) Pharmaceutical bulk drugs and chemicals such as Mineral Salts of Gluconates, Citrates, Lactates, Lactobionates, Fumarates, Orotates etc.

1400

--

Job Work by conversion (Spray Drier Process) Calcium Glubionate , Calcium Borogluconate Calcium lacto Gluconate, and other Mineral Salts

1215

--

API Products (Active Pharma Ingredients) such as Iron sucrose, Calcium dobesylate, Tiemonium methyl sulphate, Ethamsylate Tolperisone hcl, Calcium glycerophosphate, Magnesium glycerophosphate, Carbasalate calcium, Calcium d-saccharate, Alendronate sodium, Benfotiamine, Calcium folinate, Sodium beta glycerphosphate, Phenrocoumon

--

60

6. Category of Project ie. “A” or “B” : Category “A”

7. Does it attract the general condition? If yes, please specify.

: Yes. Tamil Nadu – Karnataka State Border at 2.50 km from Project Site Boundary

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

: No.

Form 1 GCPL 2

9. Location

Plot/Survey/Khasra No. : Plot No. 125 & 126, SIPCOT Industrial Complex, Hosur.

Village : Hosur

Tehsil : Hosur

District : Krishnagiri

State : Tamil Nadu

10. Nearest railway station/airport alongwith distance in kms.

: Railway Station - Hosur – 6.0 km Airport - Bangalore - 52 km

11. Nearest Town, City, District Headquarters alongwith distance in kms.

: Town - Hosur - 4.0 km City - Bangalore – 35 km District Headquarters –Krishnagiri– 50 km

12. Village Panchayats, Zilla Parishad,

Municipal Corporation, Local Body

(complete postal addresses with

telephone nos. to be given).

: Hosur Municipality

13. Name of the applicant : Mr. Arif Vazirali

14. Registered Address : # 125, 126 SIPCOT Industrial Complex, Phase – 1, Hosur – 635 126.

15. Address for correspondence : # 125, 126 SIPCOT Industrial Complex, Phase – 1, Hosur – 635 126.

Name : Mr. Arif Vazirali

Designation (Owner/Partner/CEO) : Managing Director

Address # 125, 126 SIPCOT Industrial Complex, Hosur.

Pin Code 635 126

E-mail [email protected]

Telephone No. 04344 - 406000 / 276958 / 276959

Fax No. 04344-276359.

16. Details of Alternative Sites examined,

if any.

Location of these sites should be

shown on a toposheet.

: Not Applicable. (This is proposed

Expansion / Augmentation within

existing plant)

17. Interlined Projects : None

18. Whether separate application of

interlined project has been submitted

: Not Applicable

19. If yes, date of submission : Not Applicable

20. If no, reason : -

mailto:[email protected]

Form 1 GCPL 3

21. Whether the proposal involves approval/clearance under: (a) The Forest (Conservation) Act, 1980

(b) The Wildlife (Protection) Act, 1972 (c) The C.R.Z Notification, 1991

: No

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

: Yes, SIPCOT Industrial Estate, A Notified Industrial Estate.

23. Forest land involved (hectares) : No

24. Whether there is any litigation pending against the project and / or land in which the project is proposed 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.

: Nil

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 proposed plant is an expansion / augmentation within the existing plant located in Plot No. 125 & 126, SIPCOT Industrial Complex, Hosur, Krishnagiri District, Tamil Nadu, which is a Notified Industrial Complex. The plant already exists in this SIPCOT Industrial Complex. The land use is Industrial. Hence, there is no change in land use.

1.2 Clearance of existing land, vegetation and buildings?

No

1.3 Creation of new land uses? No

1.4 Pre-construction investigations e.g. bore houses, soil testing?

No -

1.5 Construction works? Yes Construction of shop floor using Steel Structure of 748 sq.m.

1.6 Demolition works? No -.

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

No -

Form 1 GCPL 4

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

Yes Please refer Annexure-I

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 Please refer Annexure-II

1.14 Facilities for storage of goods or materials?

Yes Please refer Annexure –I

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

Yes Please refer Annexure-III

1.16 Facilities for long term housing of operational workers?

No -

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

Yes Although the existing work force and transportation will exist, there will only be a marginal increase in Traffic.

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

No The entire transportation is by road. The plant is already well connected by road, approximately 1.0 km from NH 7.

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? None However, Hosur Lake – 3.0 km & Then Pennaiyar – 12.0 km.

1.23 Abstraction or transfers of water form ground or surface waters?

No Source of water from Recycling through ETP/2 stage R.O/ Evaporator and SIPCOT. Water Balance is 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 Movement of raw material & product by road. Existing Work Force 140 Nos commute through road.

1.26 Long-term dismantling or decommissioning or restoration works?

No -

Form 1 GCPL 5

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?

No The existing workforce of 140 nos will exist upon augmentation.

1.29 Introduction of alien species? No -

1.30 Loss of native species or genetic diversity?

No -

1.31 Any other actions? - -


2.1 Land especially undeveloped or agricultural land (ha)

No Existing Land Area – 2.32 ha. Proposed Expansion & Augmentation within this land area, which is located in a well developed Notified Industrial Complex.

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

Yes A fullfledged ETP with 2 stage RO/Evaporator provided to recycle the treated waste water in process and make-up water met through SIPCOT supply. Please refer Water balance diagram in Annexure III.

2.3 Minerals (MT) No -

2.4 Construction material - stone, aggregates, sand / soil (expected source – MT)

Yes Proposed Expansion / Augmentation within the existing plant. However, construction of shop floor using steel structure of 748 sq.m.

2.5 Forests and timber (source – MT) No -

2.6 Energy including electricity and fuels (source, competing users) Unit: fuel (MT), energy (MW)

Yes Power Consumption Source Existing Upon

Expansion TNEB 0.9 MW 1.2 MW

2.7 Any other natural resources (use appropriate standard units)

No -

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):

Form 1 GCPL 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.


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 There are no hazardous substances as per MSIHC in the existing operation. However, there will be hazardous substances used in the proposed activities. The Non-Hazardous and Hazardous substances are listed in Annexure IV.

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

None -

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

Yes Betterment in the socio – economic condition of employees.

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

None -

3.5 Any other causes No -

4. Production of solid wastes during construction or operation or

decommissioning (MT/month)


4.1 Spoil, overburden or mine wastes No -

4.2 Municipal waste (domestic and or commercial wastes)

Yes Domestic Waste – 0.4 TPA

4.3 Hazardous wastes (as per Hazardous Waste Management Rules)


4.4 Other industrial process wastes Yes Please refer Annexure-III

4.5 Surplus product

No -

4.6 Sewage sludge or other sludge from effluent treatment


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 - -

Form 1 GCPL 7

5. Release of pollutants or any hazardous, toxic or noxious substances to air

(Kg/hr)


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

Yes D.G.Set is used only during emergency or grid failure.

5.2 Emissions from production processes Yes Please refer Annexure –V.

5.3 Emissions from materials handling including storage or transport

Yes Vehicular emission

5.4 Emissions from construction activities including plant and equipment

Yes Emission from diesel operated pumps, concrete mixers, vibrators and excavators. However these equipments will be maintained properly to ensure minimum emissions, more-over construction activity will be for a short duration of period.

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

Yes The operation is such that there will be insignificant dust generation. However, any semblance of odour impact on the ambient environment is controlled by measures to control odour.

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 - -

6. Generation of Noise and Vibration, and Emissions of Light and Heat


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

Yes Only significant source of noise is blowers, otherwise there are no major noise generation sources. 6.2 From industrial or similar processes Yes

6.3 From construction or demolition Yes During construction, operation of construction equipments will result in intermittent noise.

6.4 From blasting or piling No -

6.5 From construction or operational traffic

Yes Noise due to movement of trucks carrying raw materials/products.

Form 1 GCPL 8

6.6 From lighting or cooling systems No -

6.7 From any other sources - -

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


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

Yes Handling, Storage of raw material & during process. Safety measures based on maximum credible accident analysis and Risk Assessment proposed to be implemented.

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

Yes Entire of treated waste water of about 70.61 Cu.m/day is reused in process. No major sources of Air Pollution. Hazardous waste 113.5 TPA is disposed in common hazardous landfill site of TNWML.

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

Yes

7.4 From any other sources No -

7.5 Is there a risk of long term build up of pollutants in the environment from these sources?

No -

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

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

Yes Handling, Storage of raw material & during process. Safety measures based on maximum credible accident analysis and Risk Assessment.

8.2 From any other causes No -

8.3 Could the project be affected by natural disasters causing environmental damage (e.g. floods, earthquakes, landslides, cloudburst etc)?

Yes -

Form 1 GCPL 9

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

9.1 Lead to development of supporting utilities, 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 There will be growth in ancillary industries and indirect benefits in terms of trade, commerce etc. due to additional employment, and material handling.

9.2 Lead to after-use of the site, which could have an impact on the environment

No -

9.3 Set a precedent for later developments

Yes Experience in good environment management system including proper maintenance and upkeep of pollution control equipments to maintain emission within standards, maintaining extensive green belt, and good house keeping shall all accrue rich precedents for future developments. Reuse & Recycle of treated waste water using 2-stage RO/Evaporator.

9.4 Have cumulative effects due to proximity to other existing or planned projects with similar effects

No The plant site is located in an exclusive industrial area.

S.No. Areas Name/ Identity

Aerial 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

None -

III Environmental Sensitivity

Form 1 GCPL 10

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

Yes Hosur Lake – 3.0 km & Then Pennaiyar – 12.0 km

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

None -

4. Inland, coastal, marine or underground waters


5. State, National boundaries Yes Tamil Nadu – Karnataka Interstate Boundary - 2.5 km

6. Routes or facilities used by the public for access to recreation or other tourist, pilgrim areas

Yes National Highways NH-7 leads to Bangalore/Chennai/Salem

7. Defense installations

None -

8. Densely populated or built-up area

Yes Hosur – 4.0 Kms

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

Yes Hosur – 4.0 Kms

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


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

None -

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)

-- Seismically, this area is categorized under Zone-II as per IS-1893 (Part-1)-2002.

Form 1 GCPL 11

IV Proposed Terms of Reference for

EIA studies Please refer Annexure VI

“I hereby given undertaking that the 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 give, if any to the project will be revoked at our risk and cost”.

For Global Calcium Private Limited., Date : 17/04/2014 Place : Chennai

Mr. Arif Vazirali, Managing Director.

Global Calcium Private Limited.

# 125 & 126, SIPCOT Industrial Complex, Hosur, Krishnagiri District,

Tamil Nadu.

Signature of the applicant With Name and Full Address

(Project Proponent / Authorised Signatory)

Annexures GCPL 12

ANNEXURE – I PLANT LAYOUT

Annexures GCPL 13

Annexures GCPL 14

Annexures GCPL 15

ANNEXURE – II MANUFACTURING PROCESS

Annexures GCPL 16

EXISITNG MANUFACTURING PROCESS

The process to produce Ca lciu m Glucon a t e, S od iu m Glu con a t e, P ot a ssium

Glu cona t e, Ma gn esiu m Glu ocon a t e, Zin c Glou con a t e, Ma n ga n ese

Glu cona t e involves the following process

Calcula ted Quant ity of Dext r ose Mon o Hyd r a t e and S od iu m Br om id e

a re dissolved in DM Wa t er and Neut ra lized to obta in Glu con ic Acid .

Gluconic Acid thus obta ined is Neut ra lized based on the S a l t of

Glu cona t e required by either Ca lciu m Ca r bon a t e, S od iu m

Ca r bon a t e, P ot a ssiu m Ca r bon a t e, Ma gn esiu m Ca r bon a t e, Zinc

Ca r obon a t e, Ma n ga n ese Ca r bona t e .

The Neut ra lized Salt is then Fil t er ed , Cr yst a l l iz ed , Cen t r i fu ged ,

Dr ied , Mi l led a nd Pa ck ed .

In the Alterna te Process Gluconic Acid is Neut ra lized with respect ive

Sa lt s to obta in respect ive Glucona tes which is then F iltered,

Crysta llized, Cent r ifuged, Dr ied, Milled & Packed.

In the Alterna te Process using Spray Dried, Sa lt s of Glucona tes a re

F iltered, Dr ied & Packed.

CALCIUM LACTATE

ELECTROLYSIS NEUTRALISATION FILTERATION

CRYSTALLISATION

PACKING MILLING DRYING CENTRIFUGING

Annexures GCPL 17

Calcium Carbona te is Neut ra lized with Lact ic Acid and then F iltered,

Crysta lised, Cent r ifuged, Dr ied & Packed.

CALCIUM GLUBIONATE

Calcula ted quant it ies of Ca lcium Glucona te & Calcium Lactobiona te a re

Blended, Sieved and Packed.

In the Alterna te Process ca lcu la ted quant it ies of Ca lcium Glucona te and

Ca lcium Lactobina te a re dissolved in DM Water and then F iltered, Dr ied

Sieved & Packed.

CALCIUM LACTO GLUCONATE

Calcula ted quant it ies of Ca lcium Lacta te & Calcium Glucona te a re

Blended, Sieved and Packed.

In the Alterna te Spray Drier Process Ca lcium Lacta te & Calcium

Glucona te a re dissolved in DM Water and then F iltered, Dr ied Sieved &

Packed.

In another Process either Gluconic Acid or Glucono Delta Lactone a re

Neut ra lized with Lact ic Acid and Ca lcium Carbona te, the product thus

obta ined is F iltered, Dr ied, Sieved and Packed.

CALCIUM LACTOBIONATE

Calcula ted quant it ies of Lactose, Sodium Bromide, Ca lcium Carbona te

a re mixed in Water and elect rolyzed.

The product is F iltered, Vaccum Concent ra ted, Crysta llized with Alcohol,

Cent r ifuged, Milled, Dr ied and Packed.

FERROUS GLUCONATE

Calcium Glucona te & Ferrous Sulpha te a re mixed with DM Water .

The Product is then F iltered, Concent ra ted, Dr ied, Milled and Packed.

Annexures GCPL 18

PROPOSED MANUFACTURING PROCESS

IRON SUCROSE

Ferr ic Chlor ide is dissolved in wa ter and sodium bica rbona te solu t ion is added

to precipita te fer r ic hydroxide which is filt ered.

Above fer r ic hydroxide is mixed with sucrose and hea ted to get iron sucrose in

solu t ion . Which is concent ra ted to get th ick mass which is added with vigorous

st ir r ing to DNS and then methanol to precipita te iron sucrose solid. This is

cent r ifuged and slur r ied with DNS a nd acetone aga in to remove the impur it ies.

The wet materia l is dr ied under vacuum, pulver ized, redr ied, milled, blended as

needed and packed.

TIEMMONIUM METHYL SULP FATE (TMS)

Morpholine is reacted with 2-acetyl th iophene and p-formaldehyde in the

presence of hydrochlor ic acid in dena tured spir it (DNS) to get the cor responding

mannich base as HCl sa lt . The above HCl sa lt is basified in toluene to get the

corresponding mannich ketone base. This is reacted with phenyl magnesium

bromide in tet rahydrofuran t o get t iemmonium hydrochlor ide which is pur ified

using methanol slur ry. The pure hydrochlor ide is conver ted to base and t rea ted

with dimethyl su lfa te in acetone to get the t iemmonium methyl su lfa te. This is

dr ied in a vacuum oven, milled, blended and pack ed.

P ERAZINE DIMALEATE

Stage – I: N-methyl piperazine is reacted with Bromochloro propane in

presence of sodium hydroxide.

Stage – II: condensa t ion of phenoth iazine with stage –I product in DMF

(Dimethyl formamide) to form Perazine base.

Stage – III: Perazine base reacted with Maleic acid in acetone to form Perazine

Dimalea te.

Annexures GCPL 19

CALCIUM D-SACHARIDE (CADS)

Nit r ic acid reacted with Dext rose monohydra te (DMH) a t hot condit ion . The

reacted mass is basified with Potassium hydroxide. Aga in the mass is acidified

to get mono potassium sa lt of D-sachar ic acid. This sa lt is reacted with Sodium

hydroxide. The mass is reacted with Ca lcium chlor ide to form Calcium D-

sachar ide.

ALENDRONATE SODIUM

4-aminobutyr ic acid is t rea ted with a mixture of phosphorous t r ich lor ide in

presence of methane su lphonic acid a t 70 deg.C Then hydrolysed by refluxing

with wa ter and then t rea ted with sodium hydroxide to get the required

product .

P HENP ROCOUMON

Mixture of 1-phenyl-1-propanol and 4-hydroxy coumarin hea ted to reflux in

ethylene ch lor ide. The react ion mass is extracted with sodium hydroxide. Then

acidified with HCl to get the product . The crude product is pu r ified with DNS.

STRONTIUM RANELATE

Stage-I: ethyl acetone dica rboxila te is made by react ing cit r ic acid with

ch lorosulfonic acid in methylene ch lor ide

Stage – II: ethyl acetone dica rboxila te is condensed with , Malano nit r ile and

Sulphur in presence of t r iethylamine to get stage-II

Stage –III: Stage –II is reacted with Methyl bromoaceta te and Potassium

carbona te in Acetone, and to get a lkyla ted Stage –II.

Stage –IV: Stage –III reacted with st ront ium hydroxide in wa ter under reflux

condit ion to get the fina l product which is washed with wa ter ,

dr ied, milled and packed.

Annexures GCPL 20

CALCIUM GLYCEROP HOSP HATE

Stage – I: Epichlorohydr in is hydrolised with dilu te acid, and reacted with

Tr i sodium phospha te, to get Crude sodium Glycerophospha te.

Stage –II : To the Above crude Sodium Glycerophospha te solu t ion , Ca lcium

chlor ide is added to get Crude Ca lcium Glycerophospha te

Stage–III: Crude Ca lcium Glycerophospha te is washed with DNS: Water

mixture to get Pure Ca lcium Glycerophospha te, which is

cent r ifuged and dr ied

MAGNESIUM GLYCEROP HOSP HATE


Tr i sodium phospha te, to get Crude sodium Glycerophospha te.

Stage –II : To the Above crude Sodium Glycerophospha te solu t ion

,Magnesium ch lor ide is added to get Crude Magnesium

Glycerophospha te

Stage – III : Crude Magnesium Glycerophospha te is washed with DNS: Water

mixture to get Pure Magnesium Glycerophospha te, which is

cent r ifuged and dr ied

SODIUM GLYCEROP HOSP HATE


Tr i sodium phospha te, to get Crude sodium Glycerophospha te

solu t ion which is concent ra ted and filt ered to get Crude sodium

Glycerophospha te

Stage–II: Crude Sodium Glycerophospha te is washed with DNS: Water

mixture to get Pure Sodium Glycerophospha te, which is

en t r ifuged and dr ied

.

SODIUM BETA GLYCEROP HOSP HATE

Stage – I : Glycerol is reacted react ion with pivaloyl ch lor ide in presence

pyr idine in Methyl t er t ia ry butyl ether to get dipiva loyl glycerol,

which is reacted with phosphorous oxychlor ide in presence of

Tr iethylamine.

Stage – II : Stage I is quenched with wa ter . And ext racted with hexane and

methanol: wa ter

Annexures GCPL 21

Stage – III: Methanol –water mixture is basified with sodium hydroxide to the

beta sodium salt which is Cent r ifuged and dr ied.

CARBASALATE CALCIUM

Aspir in is dissolved in wa ter using sodium bica rbona te. This clea r solu t ion is

reacted with urea and ca lcium chlor ide solu t ion to get ca rbasa la te ca lcium

precipita ted which is Cent r ifuged, washed with DNS and dr ied.

ETHAMSYLATE

Stage-I: Sulphur ic acid is added to a suspen sion of hydroquinone in

ethylene di ch lor ide. After the su lfona t ion , wa ter is added and

aqueous layer separa ted.

Stage-II: Aqueous layer is neut ra lized with diethylamine, concent ra ted,

ch illed, the product filt ered and washed with isop ropanol and

dr ied.

CALCIUM DOBESYLATE

Stage-I: Sulphur ic acid is added to a suspent ion of hydroquinone in

ethylene di ch lor ide. After the su lfona t ion , wa ter is added and

aqueous layer separa ted.

Stage-II: Aqueous layer is neutra lized with a slur ry of ca lcium carbona te in

wa ter , cent r ifuged to separa te ca lcium sulfa te.

Liquid from cent r ifuge is concent ra ted, ch illed, the product filt ered and washed

with isopropanol and dr ied.

Annexures GCPL 22

ANNEXURE – III WATER BALANCE &

WASTE MANAGEMENT

Annexures GCPL 23

Water Balance Diagram All Values are in KL Existing [ ] Proposed ( )

Evapora tion [27] + (5.54) = 32.54

Waste w ate r [38] + (7.8) = 45.8

Evaporation [27] + (4) = 31

Waste w ate r [18] + (2.6) = 20.6

Evaporation [1.4] + (0.2) = 1.6

Waste w ate r [5.6] + (0.8) = 6.4

P e rm e ate Re cycle d w ate r [59.75] + (10.86) = 70.61

[142] + (20.94) =

162.94

Coolin g w ate r /

F loor w ash

[45] + (6.6) = 51.6

P roce ss /Boile r/

Equ ipm e n t Cle an in g

[65] + (13.34) = 78.34

Domestic [7] + (1) = 8

Garde n [25] KL

ETP

[61.6] + (11.2)

= 72.8

RO

SIPCOT / Outsourced

[82.25] + (10.08) = 92.33

ME

[59

.75

] +

(1

0.8

6)

=

70

.61

Evaporation

Res idu e 0.65 kg

Annexures GCPL 24

The general scheme for Wastewater Management at GCPL

Domestic Wastewater

Floor Washing & Equipment Cleaning Wastewater

Cooling Tower & Boiler Blow Down

SIPCOT Sewer

3 Stage Anaerobic Contact Filter

DM Plant Regenerant Waste

Neutralisa-tion Pit

RO Plant

Mechanical Evaporator

Dry solids

Collection sump

Treated water for reuse

Settling Tank

Rejects

Aerated Lagoon I

Settling Tank

Filter Press

Sludge Recycle

Aerated Lagoon II

Settling Tank

Collection Tank

Annexures GCPL 25

The process of treatment of Trade Effluent

At GCPL, trade effluent is generated from the floor washings and equipment

cleaning. The total quantity of this trade effluent generated upon expansion will be

72.8 Cu.m/d.

The trade effluent generated from floor washings/equipment cleanings is collected

in a collection tank.

At the inlet of the tank, hydrated lime slurry is added to effect neutralisation.

The neutralised waste is then pumped to flow control tank, from where the waste is

allowed to discharge into a settling tank.

The overflow from the settling tank is allowed to pass through a three stage

anaerobic contact filter.

After anaerobic treatment, the waste is aerobically treated in an aerated lagoon.

The treated wastewater from the lagoon is allowed to settle in a settling tank and is

pumped to aerated lagoon II, wherein polyelectrolyte is added for better floc

formation to enable easy settling of suspended particles.

The aerated water is then taken to settling tank II, from where the clear supernatant

is pumped into the collection tank.

The treated water is then passed through the RO plant. Treated water from RO is

reused and the RO rejects are subject to Mechanical evaporation. Condensed

water from Mechanical evaporator is also reused.

Annexures GCPL 26

Treatment Plant Performance

To assess the adequacy of treatment plant, samples were collected at the various stages

of treatment at specified time intervals. The samples thus collected were analysed and the

analysis of results is given in the following table.

Characteristics of Treated and Untreated Trade Effluent

S.No Parameters Unit Value

Untreated Treated

1. PH 4.43 7.5 - 8.0

2. BOD - 3 day at 270C mg/l 6250 <30

3. COD mg/l 10483 <200

4. Total Suspended Solids mg/l 290 <40

5. Total Dissolved Solids mg/l 18500 <2100

6. Chlorides mg/l 1290 <800

7. Sulphates mg/l 156 <100

8. Oil & Grease mg/l 4.0 <1.0

S.

No.

Details Dimension

L x B x H in mts

Capacity in lts Qty

EFFULUENT TREATMENT PLANT / EQUIPMENT CAPACITY 1 Effluent Treatment Plant 60000 lts/ day 60000 lts / day 1 No

2 RO Plant 4000 Lts / hr 4000 lts/ hr 1 No

3 Multiple Effect Evaporator 800 lts/ hr 800 lts/ hr 1 No

4 Electro Coagulation Plant 4000 lts / hr 4000 lts/ hr 2 Nos

5 Boiler 2 Ton / Hr 2 Ton / Hr 1 No

6 Cooling Tower 150 TR 150 TR 1 N0

7 Trade Effluent Pump 2 Hp 2 Hp 1 No

8 Surface Aerator 7.5 Hp 7.5 Hp 2 No

9 Floating Areator 5HP 5 HP 4 Nos

10 Sludge circulation Pump 2 Hp 2 Hp 1 No

11 Effluent Pump 5 Hp 5 hP 1 No

12 Treated water Collection Pump 2 Hp 2 hp 1 No

13 Final Treated Water Collection Pump 2 HP 2Hp 1 No

ETP / RO Tank details 14 Septic Tank & septic water collection 6.5 x 3.5 x 3 &

1.5 x 3.5 x 3

65000 1 set

15 Raw effluent collection Tank - 1 4 x 3.4 x 2.1 15750 1 No

16 Raw effluent collection Tank-2 2.8 x 2.6 x 1.9 13500 1 No

17 Anerobic lagoon -1 4.4 x 2.9 x 3.4 15750 1 No

18 Anerobic lagoon -2 12.3 x 14.2 x 4.4 750000 1No

19 Aeration Tank - 1 11.5 x 11 x 1.8 225000 1 No

20 Aeration Tank -2 11.5 x 11 x 1.8 225000 1 No

21 Bio sludge settling Tank 3.1 dia x 1.2 deep 10000 lts 1 No

22 Chemical sludge settling Tank 3.1 dia x 1.2 Deep 10000 lts 1 No

23 Bio sludge settling bed 3.7 x 2 x 1.25 9250 lts 2 Nos

24 Chemical sludge settling bed 2 x 2 x 1.25 5000 lts 2 Nos

25 Centrifuge 250 kg 250 kg 1 No

26 Sand filter 600 dia 600 dia 1 No

27 Treated water collection tank 2.4 x 2.4 x 1.8 10000 lts 1 No

28 Final Treated water collection Tank 3.5 x 2 x 1.25 11000 1 No

29 RO Plant feed water collection Tank 6 x 4 x 2 48000 lts 1 No

30 UF water collection Tank 10000 lts 10000 Lts 1 No

31 RO reject water collection Tank 2 x 2 x 2 8000 Lts 1 No

32 RO Pure Water collection Tank 4 x 2 x 2 16000 Lts 1No

Annexures GCPL 27

SOLID WASTE

Sl. No. Type of Solid

Waste

Quantity TPA

Existing Proposed

Hazardous Non-

Hazardous

Hazardous Non-

Hazardous

1. Process Waste -- 3.0 18.875 113.5

2. ETP Sludge -- 1.5

Hazardous wastes from the production process are collected and stored in closed

containers. The containers containing the Hazardous waste is stored in a closed shed. The

Hazardous waste is disposed to common waste collection yard of Tamil Nadu Waste

Management Limited at Gummidipoondi, Tiruvallur District.

Annexures GCPL 28

ANNEXURE – IV RAW MATERIAL

Annexures GCPL 29

Existing List of Raw Materials - Non Hazardous

List of Raw Mate ria l to be u se d at

a ll s tage s of Man u factu re r

Qu an tity ( Ton P er

Mon th ) for th e fu ll

produ ction Capacity

Qu an tity pe r

An n um

Dext rose mono hydrate 174.667 2096.004

Sodium bromide / pota ssium bromide 10.291 123.492

Gluconic acid ( Alternate to 1 &2) 338.33 4059.96

Potassium Carbonate / Potassium

Bicarbonate

2.083 24.996

Calcium carbonate 47.122 565.464

Sodium Carbonate / Sodium bicarbonate 0.593 7.116

Zinc carbonate / Zinc Oxide 1.25 15.0

Magnesium Carbonate / Magnesium

oxide

1.083 12.996

Manganese Carbonate / Manganese

Oxide

0.833 9.996

Lact ic acid 104.17 1250.04

Calcium Gluconate 83.33 999.96

Calcium Lactobionate 5.417 65.004

Calcium Lacta te 125.00 1500.00

Denatured Spir it 46.533kl 558.396 Kl

Lactose 26.25 315.00

Bor ic Acid 0.25 3.0

Glucona Delta Lactone 145.83 1749.96

Fer rous Sulphate / Iron Dust 3.00 36.00

Annexures GCPL 30

Proposed List of Raw Material – Non Hazardous Sl. No

Name of the Products Name of the raw material

Quantity of Major

RM in Tons

Qty of solvent

Input in KL

Process water in

KL

1 IRON SUCROSE Ferric chloride Sucrose

22.4 70 140

3 TIEMONIUM METHYL SULPHATE

2-acetylthiophene 10.98 38.25 30

5 TOLPERISONE HCl 4-Methyl Propiophenone, 1,3-dioxalone

9.3 3 7.5

6 CALCIUM GLYCEROPHOSPHATE

108 10 70

7 MAGNESIUM GLYCEROPHOSPHATE

59.25 5 35

8 CARBASALATE CALCIUM Aspirin Urea Calcium chloride

12 2 9

9 CALCIUM D-SACCHARATE 13 1 75

10 ALENDRONATE SODIUM 4-aminobutyric acid

12.8 2 21

11 BENFOTIAMINE Thiamine hcl, Orthophosphoric acid,

37.5 6 150

12 CALCIUM FOLINATE Folic acid, sodium borohydride,

0.3 3.9 1.75

13 SODIUM BETA GLYCERPHOSPHATE

17.2 17.2 8

14 PHENROCOUMON 4-hydroxy coumarin

8.5 5.7 25

Total 329.83 178.89 608.25

Annexures GCPL 31

Proposed List of Raw Material –Hazardous

Sl. No. as per MSIHC

Name of the raw material Quantity of Major RM in Tons

319 591

Hydroquinone Sulphuric acid

13.8

408 Morpholine 10.98

319 591 196

Hydroquinone, Sulphuric acid, Diethyl amine

4.8

514 Piperidine, 9.3

506 Phosphorous trichloride 12.8

505 67

Phosphorous pentoxide, Benzoyl chloride

37.5

652 Triethyl amine 0.3

Annexures GCPL 32

ANNEXURE – V EMISSION CHARACTERISTICS

Annexures GCPL 33

Stack Emission Characteristics

Stack No 1 2 3 4 5 6 7 8 9 10 11 12 13

Material of Construction PVC PVC M.S M.S M.S M.S M.S M.S M.S M.S M.S M.S S.S

Stack attached to Electroly

tic Cells

Electroly

tic Cells

Milling/

Drying

Unit

D.G.Set

125 KVA

D.G.Set

180 KVA

D.G.Set

125 KVA

D.G.Set

180 KVA

D.G.Set

125 KVA

D.G.Set

380 KVA

D.G.Set

450 KVA

4 T

wood

Fired

BOILER

Thermo

pac

Spray

Drier

83

kg/hr

Stack height Above the ground

level in m

12.0 12.0 12.0 8.0 9.0 8.0 9.0 8.0 10.0 10.0 20.0 20.0 22.0

Stack

top

Circular/

Rectangular /

Square

Circular Circular Rectang

ular

Circular Circular Circular Circular Circular Circular Circular Circular Circular Circular

Inside dimensions of the stack

at top, mm

500 500 400 x

250

200 200 200 200 200 300 350 600 350 400

Gas quantity – m3/hr 20000 20000 3600 1690 1900 1690 1900 1690 3200 4100 16000 6000 9000

Flue gas temperature, oC 35 35 78 250 250 250 250 250 300 300 140 240 110

Exit velocity of the gas, m/s 28.0 28.0 10.0 15.0 16.8 15.0 16.8 15.0 12.6 12.0 16.0 18.5 20.0

Emission concentration , mg/m3

SO2 - - - 16.69 24.04 16.69 24.04 16.69 50.8 60.1 687 2340 -

NOx - - - 164.22 236.48 164.22 236.48 164.22 499.2 591.2 189 569 -

SPM - - 75.0 4.72 6.8 4.72 6.8 4.72 14.4 17.0 100 100 -

Br 7.53 7.53 - - - - - - - - - - -

Emission rate, g/s

SO2 - - - 0.0078 0.0127 0.0078 0.0127 0.0078 0.045 0.068 3.05 3.9 -

NOx - - - 0.077 0.125 0.077 0.125 0.077 0.444 0.673 0.84 0.95 -

SPM - - 0.075 0.0022 0.0060 0.0022 0.0060 0.0022 0.0128 0.0194 0.44 0.167 -

Br 0.04 0.04 - - - - - - - - - - -

Annexures GCPL 34

ANNEXURE – VI TERMS OF REFERENCE

Annexures GCPL 35

Terms of Reference

The Environment Impact Assessment will consist of the following,

1. Manufacturing Process details shall be included.

2. Mass balance for the raw material and products will be included

3. Ambient Air Quality monitoring at 8 locations within the study area of 10 km, aerial

coverage from project site with one AAQMS in downwind direction will be carried

out.

4. Details of water requirement, water balance chart for new unit or for existing unit as

well as proposed expansion. Measures for conservation water by recycling and

reuse to minimize the fresh water requirement.

5. Source of water supply and permission of withdrawal of water from competent

authority.

6. Water balance data including quantity of effluent generated, recycled and reused

and discharged will be provided.

7. Solid/Hazardous waste generation, storage, utilization and disposal from all the

sources. EMP will include the concept of waste-minimization, recycle/reuse/recover

techniques, Energy conservation, and natural resource conservation.

8. Risk assessment and Disaster (Emergency) Preparedness and Management Plan

including damage control needs will be addressed and included.

9. Occupational Health:

a. Details of existing Occupational & Safety Hazards. What are the exposure

levels of above mentioned hazards and whether they are within permissible

exposure level (PEL). If these are not within PEL, what measures adopted to

keep them within PEL so that health of the workers is preserved.

b. Details of exposure specific health status evaluation of worker. If the workers’

health is being evaluated by pre designed format, chest x rays, Audiometry,

Spirometry, Vision testing (Far & Near vision, colour vision and any other ocular

defect), ECG, during preplacement and periodical examinations give the details

of the same. Details regarding last month analyzed data of abovementioned

parameters as per age, sex, duration of exposure and department wise.

c. Annual report of health status of workers with special reference to Occupational

Health and Safety.

Annexures GCPL 36

d. Implementation of OHS standards as per OSHAS/USEPA.

e. Plan and fund allocation to ensure the occupational health & safety of all

contract and sub-contract workers.

10. Corporate Environment Policy:

i. Environment Policy approved by its Board of Directors?

ii. Environment Policy prescribed for standard operating process / procedures

to bring into focus any infringement / deviation / violation of the

environmental conditions?

iii. Hierarchical system or Administrative order of the company to deal with the

environmental issues and for ensuring compliance with the environmental

clearance conditions?

iv. System of reporting of non compliances / violations of environmental norms

to the Board of Directors of the company and / or shareholders or

stakeholders at large?

11. Environment Management Plan (EMP) to mitigate the adverse impacts due to the

expansion along with item wise cost will be included.

form 1 application form i basic information sl. no. item … · 2017. 6. 15. · e-mail...

Documents